U.S. patent number 10,465,850 [Application Number 15/484,239] was granted by the patent office on 2019-11-05 for method and apparatus for compressing gas in a plurality of stages to a storage tank array having a plurality of storage tanks.
This patent grant is currently assigned to New Gas Industries, L.L.C.. The grantee listed for this patent is New Gas Industries, L.L.C.. Invention is credited to Carl Guichard, Bryan Killeen, Walter H. Killeen.
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United States Patent |
10,465,850 |
Killeen , et al. |
November 5, 2019 |
Method and apparatus for compressing gas in a plurality of stages
to a storage tank array having a plurality of storage tanks
Abstract
A method and apparatus for compressing gases and supplying fuel
to a gaseous fuel consuming device, such as a gaseous fueled
vehicle or the like. One embodiment includes a gas compressor for
compressing the gaseous fuel to an array of tanks having
predetermined initial set points which are increasing for tanks in
the array. One embodiment provides a selecting valve having first
and second families of ports wherein the valve can be operated to
select a plurality of ports from the first family to be fluidly
connected with a plurality of ports with the second family, and
such fluid connections can be changed by operation of the
valve.
Inventors: |
Killeen; Walter H. (Mandeville,
LA), Killeen; Bryan (Mandeville, LA), Guichard; Carl
(Mandeville, LA) |
Applicant: |
Name |
City |
State |
Country |
Type |
New Gas Industries, L.L.C. |
Mandeville |
LA |
US |
|
|
Assignee: |
New Gas Industries, L.L.C.
(Mandeville, LA)
|
Family
ID: |
49210640 |
Appl.
No.: |
15/484,239 |
Filed: |
April 11, 2017 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20170314735 A1 |
Nov 2, 2017 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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13462177 |
Apr 11, 2017 |
9618158 |
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61518111 |
May 2, 2011 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F17C
5/06 (20130101); F17D 3/00 (20130101); F16K
11/085 (20130101); F16K 11/074 (20130101); F17C
2227/0337 (20130101); F17C 2205/0326 (20130101); F17C
2205/0323 (20130101); F17C 2250/0626 (20130101); F17C
2265/015 (20130101); F17C 2250/0439 (20130101); F17C
2265/012 (20130101); F17C 2270/0139 (20130101); Y10T
137/0396 (20150401); F17C 2209/234 (20130101); F17C
2227/0157 (20130101); F17C 2227/0164 (20130101); F17C
2223/0123 (20130101); F17C 2205/0335 (20130101); F17C
2227/047 (20130101); F17C 2250/032 (20130101); F17C
2250/0694 (20130101); F17C 2270/0168 (20130101); F17C
2201/0109 (20130101); F17C 2250/043 (20130101); F17C
2205/013 (20130101); F17C 2205/0341 (20130101); F17C
2205/0382 (20130101); F17C 2227/043 (20130101); F17C
2250/0495 (20130101) |
Current International
Class: |
F17C
5/06 (20060101); F16K 11/074 (20060101); F16K
11/085 (20060101); F17D 3/00 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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2433722 |
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Dec 2003 |
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CA |
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0285099 |
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Oct 1988 |
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EP |
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0916567 |
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May 1999 |
|
EP |
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1452794 |
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Sep 2004 |
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EP |
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1522430 |
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Apr 2005 |
|
EP |
|
1798416 |
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Jun 2007 |
|
EP |
|
2858041 |
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Jan 2005 |
|
FR |
|
2051716 |
|
Jan 1981 |
|
GB |
|
H0953798 |
|
Feb 1997 |
|
JP |
|
2361144 |
|
Jul 2009 |
|
RU |
|
03/018187 |
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Mar 2003 |
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WO |
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Primary Examiner: Stclair; Andrew D
Attorney, Agent or Firm: Roy Kiesel Ford Doody & North,
APLC North; Brett A.
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation of U.S. application Ser. No. 13/462,177,
filed May 2, 2012 (issuing as U.S. Pat. No. 9,618,158 on Apr. 11,
2017), which is a non-provisional of U.S. provisional patent
application Ser. No. 61/518,111, filed May 2, 2011, which are both
incorporated herein by reference.
Claims
What is claimed is:
1. A method of filling a tank with compressed gaseous fuel,
comprising the steps of: (a) providing an array of tanks comprising
a first Tank, a second Tank, a third Tank, and a fourth Tank, and a
compressor fluidly connected to the array; (b) before step "e",
taking gas from the first tank, compressing it with the compressor
and discharging the compressed gas to the second Tank in the array,
and continuing this step until one of the following conditions are
met: (i) the first tank experiences a pressure drop which reaches a
predefined pressure drop set point for the first Tank, or (ii) the
pressure in the first Tank drops to a predefined minimum set point
pressure for the first Tank, or (iii) the differential pressure
between the second Tank and the first Tank reaches a predefined set
point pressure differential; or (iv) second Tank pressure reaches a
predefined upper set point pressure for second Tank; (c) between
steps "b" and "e", taking gas from the second Tank, compressing it
with the compressor and discharging the compressed gas to the third
Tank, and continuing this step until one of the following
conditions are met: (i) second Tank experiences a pressure drop
which reaches a predefined pressure drop set point for the second
Tank, or (ii) the pressure in the second Tank drops to a predefined
minimum set point pressure for the second Tank, or (iii) the
differential pressure between the third Tank and the second Tank
reaches the predefined set point pressure differential; or (iv)
third Tank pressure reaches a predefined upper set point pressure
for third Tank; (d) between steps "c" and "e", taking gas from the
first Tank compressing it with the compressor and discharging
compressed gas to the second Tank in the array, and continuing this
step until one of the following conditions are met: (i) first tank
experiences a pressure drop which reaches the predefined pressure
drop set point for the first Tank, or (ii) the pressure in the
first Tank drops to the predefined minimum set point pressure for
the first Tank, or (iii) the differential pressure between the
second Tank and the first Tank reaches the predefined set point
pressure differential; or (iv) second Tank pressure reaches the
predefined upper set point pressure for the second Tank; (e)
between steps "d" and "f", taking gas from the second Tank,
compressing it with the compressor, and discharging compressed gas
to the third Tank in the array until one of the following
conditions are met: (i) second Tank experiences a pressure drop
which reaches a predefined pressure drop set point for the second
Tank, or (ii) the pressure in the second Tank drops to a predefined
minimum set point pressure for the second Tank, or (iii) the
differential pressure between the third Tank and the second Tank
reaches a predefined set point pressure differential; or (iv) the
third Tank pressure reaches a predefined upper set point pressure
for third Tank; (f) between steps "e" and "g" taking gas from the
third Tank, compressing it with the compressor and discharging the
compressed gas to the fourth Tank, and continuing this step until
one of the following conditions are met: (i) third Tank experiences
a pressure drop which reaches a predefined pressure drop set point
for the third Tank, or (ii) the pressure in the third Tank drops to
a predefined minimum set point pressure for the third Tank, or
(iii) the differential pressure between the fourth Tank and the
third Tank reaches a predefined set point pressure differential; or
(iv) the fourth Tank pressure reaches a predefined upper set point
pressure for fourth Tank; and (g) dispensing compressed gas from at
least two tanks of the array first to the compressor and then to a
vehicle storage tank, wherein during the method steps the
compressor is selectively fluidly connected to selected
combinations of the first, second, third, and fourth Tanks in the
array by a selector valve, and the selector valve having a
plurality of selector positions, first and second families of
ports, wherein each family of ports have a plurality of selector
ports, and wherein in a first selector position from the plurality
of selector positions for the selector a plurality of the selector
ports from the first family can be fluidly connected in two way
fluid directions to a plurality of selector ports from the second
family where the remaining ports in the first family are not
fluidly connected to each other, and in a second selector position
from the plurality of selector positions for the selector a
different plurality of ports from the first family can be fluidly
connected in two way directions to the same plurality of ports from
the second family, where the remaining ports in the first family
are not fluidly connected to each other and where in the second
selector position the ports in the second family are each fluidly
connected to a different port than fluidly connected to in the
first selector position.
2. The method of claim 1, wherein the selector valve includes a
body and the selector is rotatively connected to the body.
3. The method of claim 1, wherein a plurality of selector ports in
the first family are connected in a one way direction by a
plurality of check valves.
4. The method of claim 1, wherein rotation of the selector causes
the switching in connection between first and second selector
positions.
5. The method of claim 1, wherein the first family of selector
ports includes at least six selector ports and the second family of
selector ports includes at least two selector ports.
6. The method of claim 1, wherein in step "a" the compressor is a
single compressor of one stage.
7. The method of claim 1, further including the step of during step
"g" repeating steps "b" through "f" until the fourth Tank pressure
reaches the predefined upper set point pressures for each of the
first, second, third, and fourth Tanks.
8. The method of claim 1, further including the step of, during
step "g", repeating steps "b" through "f" in reverse order until
the fourth Tank pressure reaches the predefined upper set point
pressures for each of the first, second, third, and fourth
Tanks.
9. A method of filling a tank with compressed gaseous fuel,
comprising the steps of: (a) providing an array of tanks comprising
a first tank, second tank, third tank, and fourth tank, fifth tank,
and a compressor fluidly connected to the array; (b) before step
"c", taking gas from the first tank, compressing it with the
compressor and discharging the compressed gas to the second Tank in
the array, and continuing this step until one of the following
conditions are met: (i) first Tank experiences a pressure drop
which reaches a predefined pressure drop set point for the first
Tank, or (ii) the pressure in the first Tank drops to a predefined
minimum set point pressure for the first Tank, or (iii) the
differential pressure between the second Tank and the first Tank
reaches a predefined set point pressure differential; or (iv)
second Tank pressure reaches a predefined upper set point pressure
for second Tank; (c) between steps "b" and "d", taking gas from the
second Tank, compressing it with the compressor and discharging the
compressed gas to the third Tank, and continuing this step until
one of the following conditions are met: (i) second Tank
experiences a pressure drop which reaches a predefined pressure
drop set point for the second Tank, or (ii) the pressure in the
second Tank drops to a predefined minimum set point pressure for
the second Tank, or (iii) the differential pressure between the
third Tank and the second Tank reaches the predefined set point
pressure differential; or (iv) third Tank pressure reaches a
predefined upper set point pressure for third Tank; (d) between
steps "c" and "e", taking gas from the first Tank compressing it
with the compressor and discharging compressed gas to the second
Tank in the array, and continuing this step until one of the
following conditions are met: (i) first tank experiences a pressure
drop which reaches the predefined pressure drop set point for the
first Tank, or (ii) the pressure in the first Tank drops to the
predefined minimum set point pressure for the first Tank, or (iii)
the differential pressure between the second Tank and the first
Tank reaches the predefined set point pressure differential; or
(iv) second Tank pressure reaches the predefined upper set point
pressure for the second Tank; (e) between steps "d" and "f", taking
gas from the second Tank, compressing it with the compressor, and
discharging compressed gas to the third Tank in the array until one
of the following conditions are met: (i) second Tank experiences a
pressure drop which reaches the predefined pressure drop set point
for the second Tank, or (ii) the pressure in the second Tank drops
to the predefined minimum set point pressure for the second Tank,
or (iii) the differential pressure between the third Tank and the
second Tank reaches the predefined set point pressure differential;
or (iv) the third Tank pressure reaches the predefined upper set
point pressure for third Tank; (f) between steps "e" and "g" taking
gas from the third Tank, compressing it with the compressor and
discharging the compressed gas to the fourth tank, and continuing
this step until one of the following conditions are met: (i) third
Tank experiences a pressure drop which reaches a predefined
pressure drop set point for the third Tank, or (ii) the pressure in
the third Tank drops to the predefined minimum set point pressure
for the third Tank, or (iii) the differential pressure between the
fourth Tank and the third Tank reaches the predefined set point
pressure differential; or (iv) the fourth Tank pressure reaches a
predefined upper set point pressure for fourth Tank; and (g)
between steps "f" and "h", taking gas from the first Tank
compressing it with the compressor and discharging compressed gas
to the second Tank in the array, and continuing this step until one
of the following conditions are met: (i) first tank experiences a
pressure drop which reaches the predefined pressure drop set point
for the first Tank, or (ii) the pressure in the first Tank drops to
the predefined minimum set point pressure for the first Tank, or
(iii) the differential pressure between the second Tank and the
first Tank reaches the predefined set point pressure differential;
or (iv) second Tank pressure reaches the predefined upper set point
pressure for the second Tank; (h) between steps "g" and "i", taking
gas from the second Tank, compressing it with the compressor, and
discharging compressed gas to the third Tank in the array until one
of the following conditions are met: (i) second Tank experiences a
pressure drop which reaches the predefined pressure drop set point
for the second Tank, or (ii) the pressure in the second Tank drops
to the predefined minimum set point pressure for the second Tank,
or (iii) the differential pressure between the third Tank and the
second Tank reaches the predefined set point pressure differential;
or (iv) the third Tank pressure reaches the predefined upper set
point pressure for third Tank; (i) between steps "h" and "j" taking
gas from the third Tank, compressing it with the compressor and
discharging the compressed gas to the fourth tank, and continuing
this step until one of the following conditions are met: (i) third
Tank experiences a pressure drop which reaches the predefined
pressure drop set point for the third Tank, or (ii) the pressure in
the third Tank drops to the predefined minimum set point pressure
for the third Tank, or (iii) the differential pressure between the
fourth Tank and the third Tank reaches the predefined set point
pressure differential; or (iv) the fourth Tank pressure reaches the
predefined upper set point pressure for fourth Tank; and (j)
between steps "i" and "k" taking gas from the fourth Tank,
compressing it with the compressor and discharging the compressed
gas to the fifth Tank, and continuing this step until one of the
following conditions are met: (i) fourth Tank experiences a
pressure drop which reaches a predefined pressure drop set point
for the fourth Tank, or (ii) the pressure in the fourth Tank drops
to a predefined minimum set point pressure for the fourth Tank, or
(iii) the differential pressure between the fifth Tank and the
fourth Tank reaches the predefined set point pressure differential;
or (iv) the fifth Tank pressure reaches a predefined upper set
point pressure for fifth Tank; and (k) after step "j", dispensing
compressed gas from at least two tanks of the array first to the
compressor and then to a vehicle storage tank, wherein during the
method steps the compressor is selectively fluidly connected to
selected combinations of the first, second, third, and fourth Tanks
in the array by a selector valve, and the selector valve having a
plurality of selector positions, first and second families of
ports, wherein each family of ports have a plurality of selector
ports, and wherein in a first selector position from the plurality
of selector positions for the selector a plurality of the selector
ports from the first family can be fluidly connected in two way
fluid directions to a plurality of selector ports from the second
family where the remaining ports in the first family are not
fluidly connected to each other, and in a second selector position
from the plurality of selector positions for the selector a
different plurality of ports from the first family can be fluidly
connected in two way directions to the same plurality of ports from
the second family, where the remaining ports in the first family
are not fluidly connected to each other and where in the second
selector position the ports in the second family are each fluidly
connected to a different port than fluidly connected to in the
first selector position.
10. The method of claim 9, wherein in step "a" the compressor is a
single stage hermetically sealed compressor.
11. The method of claim 9, wherein before step "k" each of the
first, second, third, fourth, and fifth Tanks each reach their
respective predefined upper set point pressures.
12. The method of claim 9, further including the step of during
step "k" repeating steps "b" through "j" until the fifth Tank
pressure reaches the predefined upper set point pressures for each
of the first, second, third, fourth, and fifth Tanks.
13. The method of claim 9, further including the step of, during
step "k", repeating steps "b" through "j" in reverse order until
the fifth Tank pressure reaches the predefined upper set point
pressures for each of the first, second, third, fourth, and fifth
Tanks.
14. A method of filling a tank with compressed gaseous fuel,
comprising the steps of: (a) providing an array of tanks comprising
a first tank, second tank, third tank, fourth tank, fifth tank, and
sixth tank a compressor fluidly connected to the array; (b) before
step "c", taking gas from the first tank, compressing it with the
compressor and discharging the compressed gas to the second Tank in
the array, and continuing this step until one of the following
conditions are met: (i) first Tank experiences a pressure drop
which reaches a predefined pressure drop set point for the first
Tank, or (ii) the pressure in the first Tank drops to a predefined
minimum set point pressure for the first Tank, or (iii) the
differential pressure between the second Tank and the first Tank
reaches a predefined set point pressure differential; or (iv)
second Tank pressure reaches a predefined upper set point pressure
for the second Tank; (c) between steps "b" and "d", taking gas from
the second Tank, compressing it with the compressor and discharging
the compressed gas to the third Tank, and continuing this step
until one of the following conditions are met: (i) second Tank
experiences a pressure drop which reaches a predefined pressure
drop set point for the second Tank, or (ii) the pressure in the
second Tank drops to a predefined minimum set point pressure for
the second Tank, or (iii) the differential pressure between the
third Tank and the second Tank reaches the predefined set point
pressure differential; or (iv) third Tank pressure reaches a
predefined upper set point pressure for third Tank; (d) between
steps "c" and "e", taking gas from the first Tank compressing it
with the compressor and discharging compressed gas to the second
Tank in the array, and continuing this step until one of the
following conditions are met: (i) first tank experiences a pressure
drop which reaches the predefined pressure drop set point for the
first Tank, or (ii) the pressure in the first Tank drops to the
predefined minimum set point pressure for the first Tank, or (iii)
the differential pressure between the second Tank and the first
Tank reaches the predefined set point pressure differential; or
(iv) second Tank pressure reaches the predefined upper set point
pressure for the second Tank; (e) between steps "d" and "f", taking
gas from the second Tank, compressing it with the compressor, and
discharging compressed gas to the third Tank in the array until one
of the following conditions are met: (i) second Tank experiences a
pressure drop which reaches the predefined pressure drop set point
for the second Tank, or (ii) the pressure in the second Tank drops
to the predefined minimum set point pressure for the second Tank,
or (iii) the differential pressure between the third Tank and the
second Tank reaches the predefined set point pressure differential;
or (iv) the third Tank pressure reaches the predefined upper set
point pressure for third Tank; (f) between steps "e" and "g" taking
gas from the third Tank, compressing it with the compressor and
discharging the compressed gas to the fourth tank, and continuing
this step until one of the following conditions are met: (i) third
Tank experiences a pressure drop which reaches a predefined
pressure drop set point for the third Tank, or (ii) the pressure in
the third Tank drops to a predefined minimum set point pressure for
the third Tank, or (iii) the differential pressure between the
fourth Tank and the third Tank reaches the predefined set point
pressure differential; or (iv) the fourth Tank pressure reaches a
predefined upper set point pressure for fourth Tank; and (g)
between steps "f" and "h", taking gas from the first Tank
compressing it with the compressor and discharging compressed gas
to the second Tank in the array, and continuing this step until one
of the following conditions are met: (i) first tank experiences a
pressure drop which reaches the predefined pressure drop set point
for the first Tank, or (ii) the pressure in the first Tank drops to
the predefined minimum set point pressure for the first Tank, or
(iii) the differential pressure between the second Tank and the
first Tank reaches the predefined set point pressure differential;
or (iv) second Tank pressure reaches the predefined upper set point
pressure for the second Tank; (h) between steps "g" and "i", taking
gas from the second Tank, compressing it with the compressor, and
discharging compressed gas to the third Tank in the array until one
of the following conditions are met: (i) second Tank experiences a
pressure drop which reaches the predefined pressure drop set point
for the second Tank, or (ii) the pressure in the second Tank drops
to the predefined minimum set point pressure for the second Tank,
or (iii) the differential pressure between the third Tank and the
second Tank reaches the predefined set point pressure differential;
or (iv) the third Tank pressure reaches the predefined upper set
point pressure for third Tank; (i) between steps "h" and "j" taking
gas from the third Tank, compressing it with the compressor and
discharging the compressed gas to the fourth tank, and continuing
this step until one of the following conditions are met: (i) third
Tank experiences a pressure drop which reaches the predefined
pressure drop set point for the third Tank, or (ii) the pressure in
the third Tank drops to the predefined minimum set point pressure
for the third Tank, or (iii) the differential pressure between the
fourth Tank and the third Tank reaches the predefined set point
pressure differential; or (iv) the fourth Tank pressure reaches the
predefined upper set point pressure for fourth Tank; and (j)
between steps "i" and "k" taking gas from the fourth Tank,
compressing it with the compressor and discharging the compressed
gas to the fifth Tank, and continuing this step until one of the
following conditions are met: (i) fourth Tank experiences a
pressure drop which reaches a predefined pressure drop set point
for the fourth Tank, or (ii) the pressure in the fourth Tank drops
to predefined minimum set point pressure for the fourth Tank, or
(iii) the differential pressure between the fifth Tank and the
fourth Tank reaches the predefined set point pressure differential;
or (iv) the fifth Tank pressure reaches a predefined upper set
point pressure for fifth Tank; and (k) between steps "j" and "1",
taking gas from the first Tank compressing it with the compressor
and discharging compressed gas to the second Tank in the array, and
continuing this step until one of the following conditions are met:
(i) first tank experiences a pressure drop which reaches the
predefined pressure drop set point for the first Tank, or (ii) the
pressure in the first Tank drops to the predefined minimum set
point pressure for the first Tank, or (iii) the differential
pressure between the second Tank and the first Tank reaches the
predefined set point pressure differential; or (iv) second Tank
pressure reaches the predefined upper set point pressure for the
second Tank; (l) between steps "k" and "m", taking gas from the
second Tank, compressing it with the compressor, and discharging
compressed gas to the third Tank in the array until one of the
following conditions are met: (i) second Tank experiences a
pressure drop which reaches the predefined pressure drop set point
for the second Tank, or (ii) the pressure in the second Tank drops
to the predefined minimum set point pressure for the second Tank,
or (iii) the differential pressure between the third Tank and the
second Tank reaches the predefined set point pressure differential;
or (iv) the third Tank pressure reaches the predefined upper set
point pressure for third Tank; (m) between steps "1" and "n" taking
gas from the third Tank, compressing it with the compressor and
discharging the compressed gas to the fourth tank, and continuing
this step until one of the following conditions are met: (i) third
Tank experiences a pressure drop which reaches the predefined
pressure drop set point for the third Tank, or (ii) the pressure in
the third Tank drops to the predefined minimum set point pressure
for the third Tank, or (iii) the differential pressure between the
fourth Tank and the third Tank reaches the predefined set point
pressure differential; or (iv) the fourth Tank pressure reaches the
predefined upper set point pressure for fourth Tank; and (n)
between steps "m" and "o" taking gas from the fourth Tank,
compressing it with the compressor and discharging the compressed
gas to the fifth Tank, and continuing this step until one of the
following conditions are met: (i) fourth Tank experiences a
pressure drop which reaches the predefined pressure drop set point
for the fourth Tank, or (ii) the pressure in the fourth Tank drops
to the predefined minimum set point pressure for the fourth Tank,
or (iii) the differential pressure between the fifth Tank and the
fourth Tank reaches the predefined set point pressure differential;
or (iv) the fifth Tank pressure reaches the predefined upper set
point pressure for fifth Tank; and (o) between steps "n" and "p"
taking gas from the fifth Tank, compressing it with the compressor
and discharging the compressed gas to the sixth Tank, and
continuing this step until one of the following conditions are met:
(i) fifth Tank experiences a pressure drop which reaches the
predefined pressure drop set point for the fifth Tank, or (ii) the
pressure in the fifth Tank drops to the predefined minimum set
point pressure for the fifth Tank, or (iii) the differential
pressure between the sixth Tank and the fifth Tank reaches the
predefined set point pressure differential; or (iv) the sixth Tank
pressure reaches a predefined upper set point pressure for sixth
Tank; and (p) after step "o", dispensing compressed gas from at
least two tanks of the array first to the compressor and then to a
vehicle storage tank, wherein during the method steps the
compressor is selectively fluidly connected to selected
combinations of the first, second, third, and fourth Tanks in the
array by at least one selector valve, and the at least one selector
valve having a plurality of selector positions, first and second
families of ports, wherein each family of ports have a plurality of
selector ports, and wherein in a first selector position from the
plurality of selector positions for the selector a plurality of the
selector ports from the first family can be fluidly connected in
two way fluid directions to a plurality of selector ports from the
second family where the remaining ports in the first family are not
fluidly connected to each other, and in a second selector position
from the plurality of selector positions for the selector a
different plurality of ports from the first family can be fluidly
connected in two way directions to the same plurality of ports from
the second family, where the remaining ports in the first family
are not fluidly connected to each other and where in the second
selector position the ports in the second family are each fluidly
connected to a different port than fluidly connected to in the
first selector position.
15. The method of claim 14, further including the step of during
step "p" repeating steps "b" through "o" until the sixth Tank
pressure reaches the predefined upper set point pressures for each
of the first, second, third, fourth, fifth, and sixth Tanks.
16. The method of claim 14, further including the step of, during
step "p", repeating steps "b" through "o" in reverse order until
the sixth Tank pressure reaches the predefined upper set point
pressures for each of the first, second, third, fourth, fifth, and
sixth Tanks.
17. The method of claim 14, wherein in step "a" the compressor is a
single compressor of one stage and hermetically sealed.
Description
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable
REFERENCE TO A "MICROFICHE APPENDIX"
Not applicable
BACKGROUND
Over the years, concerns have developed over the availability of
conventional fuels (such as gasoline or diesel fuel) for internal
combustion engine vehicles, the operating costs and fuel
efficiencies of such vehicles, and the potentially adverse effects
of vehicle emissions on the environment. Because of such concern,
much emphasis has been placed on the development of alternatives to
such conventional vehicle fuels. One area of such emphasis has been
the development of vehicles fueled by natural gas or other
methane-type gaseous fuels, either as the sole fuel or as one fuel
in a dual-fuel system. As a result, vehicles using such fuels have
been produced and are currently in use on a relatively limited
basis both domestically and abroad.
Compressed natural gas is an abundant resource in the United States
of America. It has been estimated that the known resources of
natural gas are sufficient to supply the needs of the United States
for at least 200 years.
In order to provide such gaseous fueled vehicles with a reasonable
range of travel between refuelings, it has previously been
necessary to store the on-board gaseous fuel at very high
pressures, generally in the range of approximately 2000 psig (13.9
MPa) to 3000 psig (20.7 Mpa) or higher. Without such high-pressure
on-board storage, the practical storage capacity of such vehicles
was limited because of space and weight factors to the energy
equivalent of approximately one to five gallons (3.7 to 19 liters)
of conventional gasoline. Thus, by compressing the gaseous fuel to
such high pressures, the on-board storage capacities of such
vehicles were increased.
One disadvantage of the compressed gaseous fuel systems discussed
above is that they require complex and comparatively expensive
refueling apparatus in order to compress the fuel to such high
pressures. Such refueling apparatus has therefore been found to
effectively preclude refueling the vehicle from a user's
residential natural gas supply system as being commercially
impractical.
Another alternative to the above-discussed fuel storage and vehicle
range problems, has been to store the on-board fuel in a liquid
state generally at or near atmospheric pressure in order to allow
sufficient quantities of fuel to be carried on board the vehicles
to provide reasonable travel ranges between refuelings. Such
liquified gas storage has also, however, been found to be
disadvantageous because it requires inordinately complex and
comparatively expensive cryogenic equipment, both on board the
vehicle and in the refueling station, in order to establish and
maintain the necessary low gas temperatures.
In the field of natural gas distribution and storage, there is a
need to gather fuel (natural gas, methane, or hydrogen) from the
existing pipeline distribution system. In the United States for a
residential environment, natural gas suppliers typically deliver
this gas at less than one psig. In order to carry enough natural
gas fuel for a respectable driving range, the fuel must be
compressed to at least 3,000 psig or 3,600 psig.
Many processes require the creation of extreme pressure changes.
Many well known prior art inventions use multi-stage compressors or
hydraulic rams to effect large volume changes on known gases.
Because of the mechanical limitations of the standard piston and
crankshaft designs, multi-stage compressors are often used when
attempting to compress gasses from atmosphere to pressures over 500
psig. In one embodiment, by using a specially constructed
sequencing valve, a simpler and more reliable single stage
compressor can be used, resulting in increased reliability and
significantly lower power consumption.
While a well lubricated piston and crankshaft is probably the most
reliable and well understood means of compressing a gas, numerous
other arrangements have been created to overcome its
limitations.
While certain novel features of this invention shown and described
below are pointed out in the annexed claims, the invention is not
intended to be limited to the details specified, since a person of
ordinary skill in the relevant art will understand that various
omissions, modifications, substitutions and changes in the forms
and details of the device illustrated and in its operation may be
made without departing in any way from the spirit of the present
invention. No feature of the invention is critical or essential
unless it is expressly stated as being "critical" or
"essential."
SUMMARY
The apparatus of the present invention solves the problems
confronted in the art in a simple and straightforward manner.
In one embodiment is provided a method and system for compressing
gas, the system including a compressor and an array of tanks having
predetermined initial set points which are increasing for tanks in
the array. One embodiment provides a selecting valve operatively
connecting the compressor to the tank array, the selecting valve
having first and second families of ports, with the first family of
ports operatively connected to the tank array and the second family
of ports operatively connected to the compressor, wherein the valve
can be operated to select a plurality of ports from the first
family to be fluidly connected with a plurality of ports with the
second family, and such selected plurality of ports from the first
and second families to be fluidly connected to each other can be
changed by operation of the valve.
One embodiment relates generally to a method and apparatus for
refueling transportation vehicles or other devices fueled by
natural gas or other gas.
In one embodiment is provided a method and apparatus for
compressing, storing, and delivering a gaseous fuel, and/or
supplying fuel to a gaseous fuel consuming device. In different
embodiments the method and apparatus can be used to compress
nitrogen, air, or cryogenic refrigerants.
In one embodiment is provided an apparatus having an array of at
least three staged tanks which are filled with compressed gas to
specified pressures.
In one embodiment during offloading to a vehicle to be fueled, the
gas pressures in each of the tanks can be measured, a control
system sequentially selects a first tank and withdraws gas from it
to the vehicle to be filled until the rate of gas flow is less than
optimum, the control system selects tank and withdraws gas from the
next sequential of the tanks.
In one embodiment, during the time the vehicle is being fueled, one
or more of the tanks are being replenished with compressed gas.
One embodiment provides a refueling method and apparatus that may
be manufactured significantly less expensively than those of the
prior art in a compact, modular form, and that is adapted to be
connected to a user's residential natural gas or other gaseous fuel
supply system.
Array of Increasingly Staged Pressurized Tanks
In one embodiment is provided a plurality of tanks having staged
pressure set points, where staged pressure points are
increasing.
In one embodiment there are at least 2, 3, 4, 5, 6, 7, 8, 9, 10,
11, 12, 13, 14, 15, 16, 17, 18, 19, 20 tanks. In various
embodiments there is a range of staged pressure tanks between any
two of the above referenced number of staged tanks.
In various embodiments it is contemplated that one or more of the
Tanks can include two or more smaller tanks coupled together at the
same pressure to make a larger volume tank.
In one embodiment, the stages array has a series of Tanks, T1 at
P1; T2 at P2 where P2 is greater than P1; T3 at P3 where P3 is
greater than P2; T4 at P4 where P4 is greater than P3; T5 at P5
where P5 is greater than P4; T6 at P6 where P6 is greater than P5;
T7 at P7 where P7 is greater than P6; and T8 at P8 where P8 is
greater than P7. In this embodiment, one-way check valves between
adjacent Tanks in the Tank array will prevent backwards bleeding of
pressure from higher numbered Tanks in the Tank array to lower
numbered Tanks in the Tank array. In different embodiments tanks T8
and T7 can be omitted, and/or T6, T7, and/or T8 can be comprised of
one or more tanks coupled together. Using the Same Compressor to
Recompress Gas from a First Stage Tank in Tank Array, to a Second
Stages Tank in Tank Array, and to a Third Staged Tank in Tank
Array, and to Additional Stage Tanks in Tank Array
In one embodiment, the staged tanks can be filled with compressed
gas by using the same compressor to take gas from one of the tanks,
compress it more, and discharge the gas to one of the other
tanks.
In one embodiment, is provided a hermetically sealed compressor
allowing differential compression between tanks in the tank array
where compressed gas from a first tank in the array is compressed
by the compressor and discharged to a second tank in the tank array
at a higher pressure than the maximum absolute discharge pressure
of the compressor because the hermetically sealed body allows the
compressing piston to be precharged by the input pressure of the
incoming gas from the first tank of the tank array.
In one embodiment a compressor is coupled to the Tank array where
the compressor can: (a) take a first quantity of gas from a first
Tank in the Tank Array, compress it with a compressor, and
discharge the compressed gas to a second Tank in the array; (b)
take a second quantity of gas from the second Tank in the Tank
Array, compress it with the compressor, and discharge the second
quantity compressed gas to a third Tank in the array.
In one embodiment a compressor is coupled to the Tank array where
the compressor can: (a) take a first quantity of gas from a first
Tank in the Tank Array, compress it and discharge the first
quantity of compressed gas to a second Tank in the array; (b) take
a second quantity of gas from the second Tank in the Tank Array,
compress it with the compressor, and discharge the second quantity
of compressed gas to a third Tank in the array; (c) take a third
quantity of gas from the third Tank in the Tank Array, compress it
with the compressor, and discharge the third quantity of compressed
gas to a fourth Tank in the array.
In one embodiment a compressor is coupled to the Tank array where
the compressor can: (a) take a first quantity of gas from a first
Tank in the Tank Array, compress it and discharge the first
quantity of compressed gas to a second Tank in the array; (b) take
a second quantity of gas from the second Tank in the Tank Array,
compress it with the compressor, and discharge the second quantity
of compressed gas to a third Tank in the array; (c) take a third
quantity of gas from the third Tank in the Tank Array, compress it
with the compressor, and discharge the third quantity of compressed
gas to a fourth Tank in the array; (d) take a fourth quantity of
gas from the fourth Tank in the Tank Array, compress it with the
compressor, and discharge the fourth quantity of compressed gas to
a fifth Tank in the array.
In one embodiment a compressor is coupled to the Tank array where
the compressor can: (a) take a first quantity of gas from a first
Tank in the Tank Array, compress it and discharge the first
quantity of compressed gas to a second Tank in the array; (b) take
a second quantity of gas from the second Tank in the Tank Array,
compress it with the compressor, and discharge the second quantity
of compressed gas to a third Tank in the array; (c) take a third
quantity of gas from the third Tank in the Tank Array, compress it
with the compressor, and discharge the third quantity of compressed
gas to a fourth Tank in the array; (d) take a fourth quantity of
gas from the fourth Tank in the Tank Array, compress it with the
compressor, and discharge the fourth quantity of compressed gas to
a fifth Tank in the array; (e) take a fifth quantity of gas from
the fifth Tank in the Tank Array, compress it with the compressor,
and discharge the fifth quantity of compressed gas to a sixth Tank
in the array.
In one embodiment a compressor is coupled to the Tank array where
the compressor can: (a) take a first quantity of gas from a first
Tank in the Tank Array, compress it and discharge the first
quantity of compressed gas to a second Tank in the array; (b) take
a second quantity of gas from the second Tank in the Tank Array,
compress it with the compressor, and discharge the second quantity
of compressed gas to a third Tank in the array; (c) take a third
quantity of gas from the third Tank in the Tank Array, compress it
with the compressor, and discharge the third quantity of compressed
gas to a fourth Tank in the array; (d) take a fourth quantity of
gas from the fourth Tank in the Tank Array, compress it with the
compressor, and discharge the fourth quantity of compressed gas to
a fifth Tank in the array; (e) take a fifth quantity of gas from
the fifth Tank in the Tank Array, compress it with the compressor,
and discharge the fifth quantity of compressed gas to a sixth Tank
in the array; and (f) take a sixth quantity of gas from the sixth
Tank in the Tank Array, compress it with the compressor, and
discharge the sixth quantity of compressed gas to a seventh Tank in
the array.
In one embodiment a compressor is coupled to the Tank array where
the compressor can: (a) take a first quantity of gas from a first
Tank in the Tank Array, compress it and discharge the first
quantity of compressed gas to a second Tank in the array; (b) take
a second quantity of gas from the second Tank in the Tank Array,
compress it with the compressor, and discharge the second quantity
of compressed gas to a third Tank in the array; (c) take a third
quantity of gas from the third Tank in the Tank Array, compress it
with the compressor, and discharge the third quantity of compressed
gas to a fourth Tank in the array; (d) take a fourth quantity of
gas from the fourth Tank in the Tank Array, compress it with the
compressor, and discharge the fourth quantity of compressed gas to
a fifth Tank in the array; (e) take a fifth quantity of gas from
the fifth Tank in the Tank Array, compress it with the compressor,
and discharge the fifth quantity of compressed gas to a sixth Tank
in the array.
In one embodiment a compressor is coupled to the Tank array where
the compressor can: (a) take a first quantity of gas from a first
Tank in the Tank Array, compress it and discharge the first
quantity of compressed gas to a second Tank in the array; (b) take
a second quantity of gas from the second Tank in the Tank Array,
compress it with the compressor, and discharge the second quantity
of compressed gas to a third Tank in the array; (c) take a third
quantity of gas from the third Tank in the Tank Array, compress it
with the compressor, and discharge the third quantity of compressed
gas to a fourth Tank in the array; (d) take a fourth quantity of
gas from the fourth Tank in the Tank Array, compress it with the
compressor, and discharge the fourth quantity of compressed gas to
a fifth Tank in the array; (e) take a fifth quantity of gas from
the fifth Tank in the Tank Array, compress it with the compressor,
and discharge the fifth quantity of compressed gas to a sixth Tank
in the array; (f) take a sixth quantity of gas from the sixth Tank
in the Tank Array, compress it with the compressor, and discharge
the sixth quantity of compressed gas to a seventh Tank in the
array; and (g) take a seventh quantity of gas from the sixth Tank
in the Tank Array, compress it with the compressor, and discharge
the seventh quantity of compressed gas to an eighth Tank in the
array.
In one embodiment a compressor is coupled to the Tank array where
the compressor can: (a) take a first quantity of gas from a first
Tank in the Tank Array, compress it and discharge the first
quantity of compressed gas to a second Tank in the array; (b) take
a second quantity of gas from the second Tank in the Tank Array,
compress it with the compressor, and discharge the second quantity
of compressed gas to a third Tank in the array; (c) take a third
quantity of gas from the third Tank in the Tank Array, compress it
with the compressor, and discharge the third quantity of compressed
gas to a fourth Tank in the array; (d) take a fourth quantity of
gas from the fourth Tank in the Tank Array, compress it with the
compressor, and discharge the fourth quantity of compressed gas to
a fifth Tank in the array; (e) take a fifth quantity of gas from
the fifth Tank in the Tank Array, compress it with the compressor,
and discharge the fifth quantity of compressed gas to a sixth Tank
in the array; (f) take a sixth quantity of gas from the sixth Tank
in the Tank Array, compress it with the compressor, and discharge
the sixth quantity of compressed gas to a seventh Tank in the
array; and (g) take a seventh quantity of gas from the seventh Tank
in the Tank Array, compress it with the compressor, and discharge
the seventh quantity of compressed gas to an eighth Tank in the
array; and (h) take an eighth quantity of gas from the eighth Tank
in the Tank Array, compress it with the compressor, and discharge
the eighth quantity of compressed gas to a ninth Tank in the array.
Check Valves Fluidly Connecting Directly in a One Way Direction
Adjacent Tanks, and Indirectly Non-Adjacent Tanks of Higher Numbers
in the Array
In one or more embodiments the pressure staged tanks are fluidly
coupled together (from lower pressure to higher pressure) through a
series of check valves between sets of two Tanks--where the gas can
flow from the lowered numbered tank in the array to the next higher
number Tank in the array.
In one embodiment a compressor is coupled to the Tank array where
the compressor can: (a) take a first quantity of gas from a first
Tank in the Tank Array where the first Tank is at a first Tank
first pressure, compress it with a compressor and discharge the
first quantity of compressed gas to a second Tank in the array, and
continuing this step until the first tank pressure drops to a first
Tank second pressure where the difference between the first Tank
first pressure and the first Tank second pressure is less than a
predefined first Tank pressure drop; (b) take a second quantity of
gas from a second Tank in the Tank Array where the second Tank is
at a second Tank first pressure, compress it with the compressor
and discharge the second quantity of compressed gas to a third Tank
in the array, and continuing this step until the second tank
pressure drops to a second Tank second pressure where the
difference between the second Tank first pressure and the second
Tank second pressure is less than a predefined second Tank pressure
drop; (c) take a third quantity of gas from a third Tank in the
Tank Array where the third Tank is at a third Tank first pressure,
compress it with the compressor and discharge the third quantity of
compressed gas to a fourth Tank in the array, and continuing this
step until the third tank pressure drops to a third Tank second
pressure where the difference between the third Tank first pressure
and the third Tank second pressure is less than a predefined third
Tank pressure drop; (d) take a fourth quantity of gas from a fourth
Tank in the Tank Array where the fourth Tank is at a fourth Tank
first pressure, compress it with the compressor and discharge the
fourth quantity of compressed gas to a fifth Tank in the array, and
continuing this step until the fourth tank pressure drops to a
fourth Tank second pressure where the difference between the fourth
Tank first pressure and the fourth Tank second pressure is less
than a predefined fourth Tank pressure drop; (e) take a fifth
quantity of gas from a fifth Tank in the Tank Array where the fifth
Tank is at a fifth Tank first pressure, compress it with the
compressor and discharge the fifth quantity of compressed gas to a
sixth Tank in the array, and continuing this step until the fifth
tank pressure drops to a fifth Tank second pressure where the
difference between the fifth Tank first pressure and the fifth Tank
second pressure is less than a predefined fifth Tank pressure drop;
(f) take a sixth quantity of gas from a sixth Tank in the Tank
Array where the sixth Tank is at a sixth Tank first pressure,
compress it with the compressor and discharge the sixth quantity of
compressed gas to a seventh Tank in the array, and continuing this
step until the sixth tank pressure drops to a sixth Tank second
pressure where the difference between the sixth Tank first pressure
and the sixth Tank second pressure is less than a predefined sixth
Tank pressure drop; and (g) dispense gas from at least two tanks
from the array of tanks to a vehicle storage tank.
In various embodiments the staged tanks in the staged tank array
are fluidly connected with one way valves which allow pressure to
flow in the direction from tanks having lower predefined staged
pressure points to higher predefined staged pressure points. In
various embodiments a series of check valves are used.
Offloading to Vehicle Tank
In one embodiment during operation, a line 102 is coupled to the
fuel tank of the vehicle to be refueled. A controller begins the
refueling process by first using tank 1, the lowest pressure tank,
in the tank array. Once flow from tank 1 begins to fill vehicle,
the pressure in tank 1 will decrease. At a certain point the
pressure in tank 1 will substantially equalize to the pressure in
the vehicle's tank, and flow from tank 1 to the vehicle will stop.
When flow from tank 1 ceases (e.g., as determined by the system of
a non-changing pressure in the tank after a predetermined period of
time), indicating that the vehicle's fuel tank is refilled to the
equalized pressure in tank 1, controller connects the next highest
pressure tank 2 in the array to the vehicle's fuel tank. When flow
ceases from tank 2 to the vehicle (e.g., as determined by the
system of a non-changing pressure in the tank after a predetermined
period of time), the controller connects to the next highest
pressure tank (tank 3) to fill the vehicle's fuel tank. This
process is repeated as the pressure in the vehicle fuel tank
increases until finally the highest pressure tank delivers gaseous
natural gas at 3,600 psi.
In one embodiment is provided a user interface which obtains input
on the vehicle to be offloaded such as pressure and volume. In
another embodiment is provided a method and apparatus which obtains
the user input and, based on such input, along with the staged
pressures in the tank array, volumes of individual tanks in the
tank array, and volume of tank to be filled for the user's vehicle,
starts the offloading process from an interstitially staged tank
(e.g, tank 2, 3, 4, 5, 6, and/or n-1) of an n-staged pressurized
tank array.
In one embodiment flow rate from each of the tanks in the tank
array to the vehicle can be monitored by the controller to
determine when flow from a particular tank to the vehicle has
stopped.
In one embodiment an exit valve (not shown) connected to the outlet
of the apparatus can be used to ensure that the vehicle fuel tank
is not filled to a pressure exceeding its rated working pressure
of, for example, 3,600 to 3,000 psi.
In one embodiment a gas flow meter can be connected to discharge
line to monitor the flow rate of gas being delivered to automobile.
The flow rate determined by flow meter can be sent to controller
which, in response to such information and/or information furnished
from pressure sensors, decides which tanks from tank array to
connect to each other, and/or which tanks to offload gas to
vehicle.
In one embodiment one or more valves can be remotely controlled,
such as a solenoid valve. The controller controls valves in the
tank array causing flow to change based on pressures in the tanks.
Simultaneously, or sequentially, controller can cause a compressor
operatively connected to controller to it to fill one or more tanks
in the pressurized staged tank array which is less than the desired
set point pressures for such tanks.
In one preferred embodiment, the total volume of any particular
staged tank in a staged tank array (which will be the sum of each
tank(s) fluidly connected together during compression for such
stage and an example of this is provided as tanks 1060, 1060', and
1060'' in FIG. 5, can vary from about 25 to about 200 liters. In
another embodiment, the total volume of any particular tank will
vary from about 50 to about 150 liters. In another embodiment the
size will vary from about 1 to about 120 liters, and from about 50
to about 100 liters.
During off-loading/filling of a vehicle it will be apparent that
there is preferably sequential sequencing of the tanks in the tank
array. The first tank can be accessed, the second tank is accessed,
the third tank is accessed, etc.
In another embodiment where the highest pressured staged tank is
accessed and its pressure drops below a predefined minimum for
vehicle to be considered filled, compressor can be used in
combination with one or more tanks to complete the fill. In this
embodiment, the compressor can be used to compress gas from a first
pressurized staged tank to the next higher pressurized staged tank,
then offloading from the higher pressurized staged tank to the
vehicle, or compressing from such higher pressurized staged tank
and into the vehicle.
Compressing Gas at More than 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13,
14, 15, 16, 17, 18, 19, 20 Times the Compressor's Ability to
Compress in a Single Stage
In one embodiment at compressing at a range of between any two of
the above referenced multiples of compressor ratings.
In one embodiment the compressor rating can be equal the maximum
force which the driving motor can cause to be applied to the
compressor's piston divided by the cross sectional area of the
compressor piston chamber.
Using Same Compressor, Recompressing Gas Previously Compressed by
Compressor
One embodiment includes at least 2, 3, 4, 5, 6, 7, 8, 9, 10, 11,
12, 13, 14, 15, 16, 17, 18, 19, 20 recompression stages. In various
embodiments a range of recompression stages between any two of the
above referenced number of recompression stages is envisioned.
Multiport Staging Valve Having Circular Staging Rotation
In one embodiment is provided a selecting valve having a first
family of ports having a plurality of ports and a second family of
ports having a plurality of ports, one of the first family of ports
being selectively fluidly connectable with one of the second family
of ports.
In one embodiment the first family has a plurality of ports. In one
embodiment the first family has 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12,
13, 14, 15, 16, 17, 18, 19, and 20 ports. In various embodiments
the first family has between any two of the above specified number
of ports.
In one embodiment the second family has a plurality of ports. In
one embodiment the second family has 2, 3, 4, 5, 6, 7, 8, 9, 10,
11, 12, 13, 14, 15, 16, 17, 18, 19, and 20 ports. In various
embodiments the second family has between any two of the above
specified number of ports.
In one embodiment the first family has two ports and the second
family has 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18,
19, and 20 ports. In various embodiments the first family has two
ports and the second family has between any two of the above
specified number of ports.
In one embodiment the second family of ports can be fluidly
connected in a first direction by a plurality of one way valves. In
one embodiment the one way valves can be a plurality of check
valves. In one embodiment the plurality of check valves can be
ported in the body of the valve.
In one embodiment a selector operatively connected to the first and
second family of ports is used to selectively fluidly connect a
first port from the first family to a first port from the second
family. In one embodiment the selector operatively connected to the
first and second family of ports is used to selectively fluidly
connect a second port from the first family to a second port from
the second family.
In one embodiment the selector is used to selectively switch the
fluid connection between the first port from the first family and
the first port from the second family to the first port from the
first family to a third port from the second family, and from the
second port from the first family to a fourth port from the second
family.
In one embodiment is provided a selecting valve comprising a body
having a first family of ports having a plurality of ports and a
second family of ports having a plurality of ports, and a selector
rotatably mounted with respect to the body, the selector
selectively fluidly connecting a first port from the first family
to a first port from the second family and a second port from the
first family to a second port from the second family.
In one embodiment rotation of the selector relative to the body
selectively switches the fluid connection between the first port
from the first family and the first port from the second family to
fluidly connecting the first port from the first family to a third
port from the second family, and fluidly connecting the second port
from the first family to a fourth port from the second family.
In one embodiment the selector has a circular cross section and is
rotationally connected to the body. In one embodiment the selector
has a rotational axis relative to the body. In one embodiment the
selector has at least one trunnion which rotationally connects the
selector to the body.
In one embodiment the first port of the first family includes an
opening which fluidly connects with the selector at the
intersection of the rotational axis of the selector relative to the
body. In one embodiment the second port of the second family
includes a fluid connection with the selector that is spaced apart
from the rotational axis of the selector relative to the body. In
one embodiment the fluid connection between the selector and the
second port of the second family includes an annular recess in the
body the annular recess being circular with its center aligned with
the rotational axis between the selector and the body. In one
embodiment the annular recess is in the selector. In one embodiment
the annular recess is in the body. In one embodiment mating annular
recesses are located in the selector and the body.
In one embodiment the selector includes first and second selector
fluid conduits, with the first selector fluid conduit having first
and second port connectors and the second selector fluid conduit
having first and second port connectors.
In one embodiment each port in the second family of ports includes
a plurality of conduits having first and second openings with the
second opening of each of the ports being located on a circle
having its center located on the relative axis of rotation between
the selector and the body, and with the angular spacing between
adjacent second openings connectors being the same, and the
selector having first and second conduits each having first and
second connectors, with the second connectors being located on a
circle having its center located on the relative axis of rotation
between the selector and the body, and the angular spacing between
the second connectors being a multiple of the angular spacing
between adjacent second openings of the second family of ports. In
one embodiment the angular spacing between the second connectors of
the first and second conduits is the same as the angular spacing
between adjacent second openings of the second family of ports. In
various embodiments the multiple is 1, 2, 3, 4, 5, 6, 7, 8, 9,
and/or 10.
In one embodiment, regardless of the relative angular position
between the selector and the body, the first port connector of the
first selector conduit of the selector remains fluidly connected to
the first port of the first family of ports.
In one embodiment, regardless of the relative angular position
between the selector and the body, the first port connector of the
second selector conduit of the selector remains fluidly connected
to the second port of the first family of ports.
In one embodiment, regardless of the relative angular position
between the selector and the body, the first port connector of the
first selector conduit of the selector remains fluidly connected to
the first port of the first family of ports, and the first port
connector of the second selector conduit of the selector remains
fluidly connected to the second port of the first family of
ports.
In one embodiment relative angular movement between the selector
and the body causes the first port connector of the second selector
conduit of the selector to traverse an arc having a substantially
uniform radius of curvature. In one embodiment, relative angular
movement greater than 360 degrees causes the first port connector
of the second selector conduit of the selector to move in a circle
having a radius, while the first port of the first selector conduit
of the selector rotates in a single spot about the rotational axis
between the selector and the body.
In one embodiment relative angular movement of the selector with
respect to body causes the first port of the first family to be
connected to the second port of the second family and the second
port of the first family to be connected to a port of the second
family which is not the first or second port. In one embodiment
this is the third port of the second family.
In one embodiment, relative angular rotation of selector with
respect to body of less than the angular spacing between the
adjacent second openings of second family of ports causes the first
and second conduits to change from being fluidly connected to being
fluidly disconnected between first family of ports and the second
family of ports.
By determining the angular spacing of the second openings for the
second family of ports compared to the angular spacing of the
second connectors for the first and second conduits, relative
connections between the first family of ports and the second family
of ports can be varied. For example, if the angular spacing is the
same then adjacent second openings of the second family of ports
will be fluidly connected with the first family of ports. If the
relative angular spacing is 2, then spaced apart second openings of
the second family of ports will be fluidly connected to the first
family of ports. If the spacing is 3 times, then twice spaced apart
second openings of the second family of ports will be fluidly
connected to the first family of ports. For each multiple of
spacing the formula of multiple minus 1 spaced apart second
openings of the second family of ports will be fluidly connected to
the first family of ports. In the case of 1-1, then no spaced apart
but adjacent second openings of the second family of ports will be
fluidly connected to the first family of ports.
In various embodiments the pressures set forth in the Table shown
in FIG. 65 can be the middle points for ranges that vary about 1,
2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20,
21, 22, 23, 24, 25, 26, 27, 28, 29, and 30 percent from such mid
points on either side of such midpoints. In various embodiments the
pressures can be the upper or lower points of ranges which vary
respectively downwardly or upwardly by one of the specified
percentages.
Compression of Gas at Less than X Amount of Energy Per Cubic Foot
and Up to Y Psi
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of one embodiment using an eight tank
storage array and a home source from which a single compressor can
be used to incrementally compress from lower tanks or home source
into higher tanks.
FIG. 1A is a schematic diagram showing the sequential operation of
the valve for the embodiment shown in FIG. 1 switching fluid
connections between adjacent ports when turning to allow compressor
to create staged pressurized tank array.
FIG. 2 includes the schematic diagram of FIG. 1, but with the
addition of a plurality of one way valves between the tanks in the
tank array.
FIG. 3 is a schematic diagram of one embodiment using a seven tank
storage array and a home source from which a single compressor can
be used to incrementally compress from lower tanks or home source
into higher tanks.
FIG. 4 includes the schematic diagram of FIG. 3, but with the
addition of a plurality of one way valves between the tanks in the
tank array.
FIG. 5 is a schematic diagram of one embodiment using a seven tank
storage array and a home source from which a single compressor can
be used to incrementally compress from lower tanks or home source
into higher tanks, but in this figure the highest numbered tank
includes three storage sections of which two sections can be
fluidly isolated with respect to each other during compression
and/or offloading activities. Although not shown for purposes of
clarity a plurality of one way valves between the tanks in the tank
array can be added as in other embodiments.
FIG. 6 is a schematic diagram of one embodiment using a seven tank
storage array and a home source from which a single compressor can
be used to incrementally compress from lower tanks or home source
into higher tanks, but in this figure a second compressor has been
added to pre-compress home source gas before being compressed by
the single compressor in the seven tank storage array. Although not
shown for purposes of clarity a plurality of one way valves between
the tanks in the tank array can be added as in other
embodiments.
FIG. 7 is a schematic diagram of one embodiment using an eight tank
storage array and a home source from which a single compressor can
be used to incrementally compress from lower tanks or home source
into higher tanks, where selection of suction and discharge to the
single compress can be made using a manifold and plurality of
valves for each tank in the storage tank array.
FIG. 7A shows a valve and check valve embodiment for one of the
tanks in the staged pressurized storage tank array of FIG. 7
(second tank)
FIG. 8 is a schematic diagram of a hermetically sealed single stage
compressor with a piston and cylinder compression chamber.
FIG. 9 is a perspective view of a multi family multi port selector
valve which can be used to connect the suction and discharge lines
of the compressor to selected different suction source and selected
different discharge from the compressor.
FIG. 10 is a top view of the valve of FIG. 9.
FIG. 11 is a sectional view of the valve of FIG. 9 taken along the
lines 11-11 shown in FIG. 10.
FIG. 12 is a sectional view of the valve of FIG. 9 taken along the
lines 12-12 shown in FIG. 10.
FIG. 13 is a top exploded view of the valve of FIG. 9 showing the
three main components: (1) top with selector and check valve
porting; (2) selector with selector porting; and body with selector
recess and base porting.
FIG. 14 is a bottom exploded view of the valve of FIG. 9 showing
the three main components: (1) top with selector and check valve
porting; (2) selector with selector porting; and body with selector
recess and base porting.
FIG. 15 is a side view of the top of the valve of FIG. 9 showing
both the lower selector porting and the upper check valve porting
with check valves being omitted from the check valve porting (and
with only seven selector ports included in this version for ease of
discussion) and with many parts omitted for purposes of clarity in
the discussion.
FIG. 16 is a top view of the top of the valve of FIG. 9 showing
both the lower selector porting and the upper check valve porting
with check valves placed in the check valve porting (and with only
seven selector ports included in this version for ease of
discussion).
FIG. 17 is a representative diagram of a check valve port with a
check valve included in the port).
FIG. 18 includes various views of the exploded valve of FIG. 9 (and
with only seven selector ports included in this version for drawing
clarity and ease of discussion.
FIG. 19 is a top perspective view of the top portion of the valve
of FIG. 9 showing selector and check valve porting.
FIG. 20 is a bottom perspective view of the top with selector and
check valve porting.
FIG. 21 is a top view of the top portion of the valve of FIG. 9
showing selector and check valve porting.
FIGS. 22A and 22B are bottom views of the top portion of the valve
of FIG. 9 showing selector and check valve porting.
FIG. 23 is a side view of the top portion of the valve of FIG. 9
showing selector and check valve porting.
FIG. 24 is a sectional view of the top of the valve of FIG. 9 taken
along the lines 24-24 shown in FIG. 23.
FIG. 25 is a sectional view of the top of the valve of FIG. 9 taken
along the lines 25-25 shown in FIG. 23 but with check valves
omitted for clarity.
FIG. 26 is a sectional view of the top of the valve of FIG. 9 taken
along the lines 25-25 shown in FIG. 23, this figure including check
valves in the check valve porting.
FIG. 27 is a top perspective view of one embodiment of a selector
for the valve shown in FIG. 9.
FIG. 28 is a bottom perspective view of one embodiment of a
selector for the valve shown in FIG. 9.
FIG. 29 is a side view of the selector shown in FIG. 27.
FIG. 30 is a bottom view of the selector shown in FIG. 27.
FIG. 31 is a top view of the selector shown in FIG. 27.
FIG. 32 is a sectional view of the selector of FIG. 28 taken along
the lines 32-32 shown in FIG. 31.
FIG. 33 is a sectional view of the selector of FIG. 28 taken along
the lines 33-33 shown in FIG. 31.
FIG. 34 is a top perspective view of one embodiment of a body for
the valve shown in FIG. 9.
FIG. 35 is a bottom perspective view of one embodiment of a body
for the valve shown in FIG. 9.
FIG. 36 is a side view of the body shown in FIG. 34.
FIG. 37 is a bottom view of the body shown in FIG. 34.
FIG. 38 is a top view of the body shown in FIG. 34.
FIG. 39 is a sectional view of the body of FIG. 34 taken along the
lines 39-39 shown in FIG. 38.
FIG. 40 is a schematic diagram of another embodiment of a selecting
valve which is modified from the construction of the valve shown in
FIG. 9 by having the selector porting and check valve porting in
the body of the valve instead of in the top of the valve.
FIGS. 41 and 42 show one embodiment of a sealing mechanism between
a selector and the selector porting of either the body (e.g., FIG.
40) or the top (e.g., FIG. 9).
FIG. 43 includes various embodiments of high pressure tubing
connections which can be used with one or more embodiments
disclosed in this application.
FIG. 44 is a plot diagram showing calculated pressure changes over
time of an eight stage tank array during an initial fill
process.
FIG. 45 is a plot diagram showing calculated temperature changes
over time at a compressor discharge port, with ambient air cooling
as the only means of heat dissipation.
FIG. 46 is a plot diagram showing the horse power required
throughout the completely empty System Fill Process, over 113 hours
with an average horse power consumption of 0.11.
FIG. 47 is a plot diagram of calculated tank pressures over time
during a vehicle fill, assuming a 100 L vehicle tank which begins
at 0 psig.
FIG. 48 is a plot diagram of calculated tank temperatures over time
during a vehicle fill, assuming a 100 L vehicle tank which begins
at 0 psig.
FIG. 49 is a plot diagram of calculated tank pressures over time
during a vehicle fill, assuming a 100 L vehicle tank which begins
at 1200 psig.
FIG. 50 is a plot diagram of calculated tank temperatures over time
during a vehicle fill, assuming a 100 L vehicle tank which begins
at 1200 psig.
FIG. 51 is a plot diagram of calculated tank pressures over time
during a vehicle fill, assuming a 100 L vehicle tank which begins
at 2400 psig.
FIG. 52 is a plot diagram of calculated tank temperatures over time
during a vehicle fill, assuming a 100 L vehicle tank which begins
at 2400 psig.
FIG. 53 is a plot diagram of calculated tank pressures over time
during a vehicle fill, assuming a 100 L vehicle tank which begins
at 3420 psig.
FIG. 54 is a plot diagram of calculated tank temperatures over time
during a vehicle fill, assuming a 100 L vehicle tank which begins
at 3420 psig.
FIG. 55 is a plot diagram of calculated tank pressures over time
during a system refresh fill, assuming that the system has
previously offloaded gas to a 100 L vehicle tank which began at 0
psig. This is also an example of WAVE Option #5 step
methodology.
FIG. 56 is a plot diagram of calculated tank pressures over time
during a system refresh fill, assuming that the system has
previously offloaded gas to a 100 L vehicle tank which began at
1200 psig. This is also an example of WAVE Option #5 step
methodology.
FIG. 57 is a plot diagram of calculated tank pressures over time
during a system refresh fill, assuming that the system has
previously offloaded gas to a 100 L vehicle tank which began at
2400 psig. This is also an example of WAVE Option #5 step
methodology.
FIG. 58 is a plot diagram of calculated tank pressures over time
during a system refresh fill, assuming that the system has
previously offloaded gas to a 100 L vehicle tank which began at
3420 psig. This is also an example of WAVE Option #5 step
methodology.
FIG. 59 is a graph comparing efficiency for a typical 4 stage
compressor vs. the WAVE methodology.
FIG. 60 is a process flow diagram showing an initial or refresh
fill.
FIG. 61 is a process flow diagram showing a method determination
and an off-load transfer via pressure equalization.
FIG. 62 is a process flow diagram showing off-load tank
sequencing.
FIG. 63 is a process flow diagram showing a system reconfigure and
off-load tank sequencing.
FIG. 64 is a process flow diagram showing a system refresh
process.
FIG. 65 is a table describing a system optimized sizing for a given
100 L, 3,000 psig and/or 3,600 psig destination need.
DETAILED DESCRIPTION
Detailed descriptions of one or more preferred embodiments are
provided herein. It is to be understood, however, that the present
invention may be embodied in various forms. Therefore, specific
details disclosed herein are not to be interpreted as limiting, but
rather as a basis for the claims and as a representative basis for
teaching one skilled in the art to employ the present invention in
any appropriate system, structure or manner.
Overall System
FIG. 1 is a schematic diagram of one embodiment using an eight tank
storage array (tanks 1010, 1020, 1030, 1040, 1050, 1060, 1070, and
1080) and a home source 17 from which a single compressor 500 can
be used to incrementally compress from lower tanks or home source
into higher tanks before ultimately using system to fill a vehicle
20 storage tank 22. FIG. 2 includes the schematic diagram of FIG.
1, but with the addition of a plurality of one way valves 1024,
1034, 1044, 1054, 1064, 1074, and 1084 between the tanks in the
tank array 1000.
In one embodiment refueling system 10 can have a compressor 500
operatively connected to a tank array 1000. In one embodiment a
valve 100 can selective and operatively connect the compressor 500
to one or more tanks in tank array 1000. Valve 100 can be a
sequencing type valve. In another embodiment, schematically shown
in FIG. 7, single sequencing valve 100 can be replaced by a series
of pairs of controllable valves in a manifold system.
In one embodiment a controller 2000 can be operatively connected to
both compressor 500 and valve 100. In one embodiment a remote panel
2100 can be used to control operation of system 10.
The number of tanks, containers, gas cylinders, or spheres which
will be used in tank array 1000 can vary, depending upon the space
available for system 10, the capacity of each tank, etc. In one
embodiment tank array 1000 can include tanks 1010, 1020, 1030,
1040, 1050, 1060, 1070, and 1080. Tanks 1010, 1020, 1030, 1040,
1050, 1060, 1070, and 1080 are adapted to receive, store, and
deliver pressurized gas. As is known to those skilled in the art,
each of tanks may be comprised of a single storage container such
as, e.g., a storage cylinder, sphere, or an non-symmetrically
shaped container. In one embodiment, however, tank array 1000
comprises a multiplicity of storage containers. Cascaded tank
arrays are well known to those skilled in the art and are
described, e.g., in U.S. Pat. Nos. 5,351,726; 5,333,465; 5,207,530;
5,052,856; 4,805,674; 3,990,248; 3,505,996; and the like. The
disclosure of each of these patents is hereby incorporated by
reference into this specification.
FIG. 1 illustrates one embodiment of a tank array 1000 which may be
used in the method and apparatus. In the embodiment the pressure of
gas inside tanks 1010, 1020, 1030, 1040, 1050, 1060, 1070, and 1080
can be monitored by pressure gauges which provide input to a
controller 2000. FIG. 1A is a schematic diagram showing the
sequential operation of valve assembly 100 for the eight tank
staged tank array 1000, and schematically showing fluid connections
between increasing pressurized tanks in staged tank array 1000.
In one embodiment refueling system 10 is preferably housed in a
small, unobtrusive module-type housing 15 (not shown for clarity)
and is designed to operate on ordinary residential electrical
supply systems (e.g. 110-230 volt systems) in order to provide a
convenient and easy-to-operate system for home refueling of a
gaseous fuel powered vehicle 20 or other device. One skilled in the
art will recognize, however, that the principles of the present
invention are equally applicable to larger versions of a gaseous
refueling system, which are adapted for commercial use and which
are capable of simultaneous multi-vehicle refueling, for
example.
In one embodiment system 10 can include a flexible outlet conduit
14, with a suitable connector at its free end, is adapted to be
releasably connected to a vehicle 20 or other gaseous fuel
consuming device in order to discharge the gaseous fuel into a
storage tank 22. System 10 can include an inlet 12 adapted to be
connected to a gaseous fuel supply 16 by means of a conventional
connector device of the type known to those skilled in the art. In
one embodiment the inlet 12 can include a separator or filter 40
(such as an oil/gas separate or desiccant filter). Fuel supply 16
can comprise a natural gas supply system such as that commonly
found in many residential and commercial facilities.
In one embodiment system 10 can also include a shut-off valve 17
for shutting down the system during extended periods of non-use or
for isolating the system from the fuel supply 16 for purposes of
servicing or repairing system 10. A gaseous fuel from the fuel
supply 16 typically at between 1/4 psig (1.72 Kpa), 1/2 psig, 3/4
psig, and/or 1 psig for example, and flows through valve 17, into
the inlet 12 of system 10. In other embodiments input source gas
pressures to system 10 can be up to 60 psig.
Although a control panel 2100 may be on housing 15 (not shown), it
is also contemplated that a remote control panel mounted can be
used which is separate and spaced away from the refueling module,
such as inside the user's home, for example.
In one embodiment the tanks in tank array 1000 and compressor can
be selectively fluidly connected in a increasingly staged manner
with respect to the suction and discharge side of compressor 500.
This can be as follows:
TABLE-US-00001 Suction Side Compressor Discharge Side Compressor
outside gas source 16 first tank 1010 first tank 1010 second tank
1020 second tank 1020 third tank 1030 third tank 1030 fourth tank
1040 fourth tank 1040 fifth tank 1050 fifth tank 1050 sixth tank
1060 sixth tank 1060 seventh tank 1070 seventh tank 1070 eighth
tank 1080
In one embodiment, selected tanks in tank array 1000 can be
selectively fluidly connected to the suction side of compressor 500
and simultaneously different selected tanks in tank array can be
selectively connected to the discharge side of the compressor 500.
Smaller Number of Tanks in Tank Array 1000
FIGS. 3 and 4 are schematic diagram of one embodiment of system 10'
using a seven tank storage array 1000 and an exterior gas supply 16
from which a single compressor 500 can be used to incrementally
compress from lower tanks or exterior gas source into higher tanks.
FIG. 4 shows the same system 10 with check valves included. The
system 10' operates similarly to the system 10 schematically shown
in FIGS. 1 and 2 but with only seven tanks instead of eight. The
smaller number of tanks will reduce the number of staged
compression steps performed by valve 100, and also incrementally
reduce the highest stages set point pressure for the highest
numbered tank (tank 1070 in this embodiment).
FIG. 5 is a schematic diagram of one embodiment using an
alternative six tank storage array 1000 and a exterior gas source
16 from which a single compressor 500 can be used to incrementally
compress from lower tanks or exterior gas source into higher tanks,
but in this figure the highest numbered tank (tank number 1070 in
this embodiment) includes three storage sections of (tanks 1060,
1060', and 1060'') of which two sections (tanks 1060' and 1060'')
can be fluidly isolated using a plurality of valves 1400 and 1410
with respect to each other during compression and/or offloading
activities (e.g., 1060 isolated with respect to tanks 1060' and
1060'' by closing valve 1400, or 1060'' isolated with respect to
1060 and 1060' by closing valve 1410). Although not shown for
purposes of clarity a plurality of one way valves between the tanks
in the tank array 1000 can be added as in other embodiments.
FIG. 6 is a schematic diagram of one embodiment using a seven tank
storage array 1000 and a exterior gas source 16 from which a single
compressor 500 can be used to incrementally compress from lower
tanks or exterior gas source into higher tanks, but in this figure
a second compressor 5000 has been added to pre-compress exterior
gas source 16 gas before being compressed by the single compressor
500 in the seven tank storage array 1000. Although not shown for
purposes of clarity a plurality of one way valves between the tanks
in the tank array 1000 can be added as in other embodiments. With
this embodiment, the inlet pressure to selector port zero 101 of
valve 100 will be increased from residential source pressure of 1
psig or less to the pressure inside tank 5100. Compressor 500 can
then incrementally compress above such pressure. This embodiment
can substantially increase the overall output of system 10 in
environments where inlet gas pressure is low because compressor
5000 would normally employ a larger volume displacement than the
compressor 500.
Manifold Embodiment
FIGS. 1-6 schematically show a single sequencing valve 100 used to
selectively fluidly connect a first selected suction tank to the
suction side of compressor 500 and a first selected discharge tank
to the discharge side of compressor 500. However, tank array 1000
can also be selectively fluidly connected to compressor 500 using a
manifold and series of controllable valves providing similar
capabilities of switching tanks from suction to discharge sides of
compressor 500.
FIG. 7 is a schematic diagram of one embodiment using an eight tank
storage array 1000 and a exterior gas source from which a single
compressor 500 can be used to incrementally compress from lower
tanks or exterior gas source into higher tanks, where selection of
suction and discharge to the single compress can be made using a
manifold and plurality of valves for each tank 1010, 1020, 1030,
1040, 1050, 1060, 1070, and 1080 in the storage tank array
1000.
FIG. 7 schematically shows tank array 1000 with manifold system and
controllable valves. In this embodiment a second series of
controllable valves (valves 1013', 1023', 1033', 1043', 1053',
1063', 1073', and 1083') can be added to replace single sequencing
valve 100 shown in other embodiments. The valves and compressor 500
are controlled by controller 2000.
In one embodiment a plurality of the tanks 1010, 1020, 1030, 1040,
1050, 1060, 1070, and 1080 can be secondarily fluidly connected to
each other (in a single flow direction) through a plurality of
valves, preferably a plurality of check valves 1024, 1034, 1044,
1054, 1064, 1074, and 1084. In one embodiment each of the tanks
1010, 1020, 1030, 1040, 1050, 1060, 1070, and 1080 can include a
controllable shutoff valve 1013, 1023, 1033, 1043, 1053, 1063,
1073, and 1083.
FIG. 7A shows an alternative valve and check valve embodiment for
one of the tanks 1010 in the staged pressurized storage tank array
of this embodiment. This embodiment would include a manual shutoff
valve to be included in each of the tanks (shutoff valve 1027 for
tank 1020).
This embodiment is not preferred because of the increased cost and
reduced reliability of the increased number of controllable valves
in system 10. Additionally, it would allow the accidental
connection of two non-adjacent tanks (e.g., tank 1080 with tank
1030), thereby causing possibly harmful differential pressure loads
on compressor 500 between suction and discharge. In addition, each
connection has a potential for leaks. On the other hand, if
properly designed, each could be connected directly to the top of
the tanks, replacing the standard tank valve. This technique would
allow for the easy re-sizing and diagnosis of a system.
General Compression Method
FIG. 1 schematically shows sequencing valve set in position 1. In
this position compressor 500 initially has its suction line 510
fluidly connected via valve 100, through zero port (Port 101) to
outside gas supply 16. Additionally, when sequencing valve 100 is
set in position 1, compressor 500 discharge output 520 goes through
separator 40, valve 524, valve 528, and line 522 into sequencing
valve 100, and into tank 1010 of tank array 1000.
When first tank 1010 has reached its predetermined pressure, the
sequencing valve 100 is rotated so that compressor 500 suction line
510 is now connected to first tank 1010 and discharge line 520 is
connected to second tank 1020. Because the gas in first tank 1010
is now at a higher density and pressure compared to exterior gas
source 16, compressor 500 now compresses additionally the higher
density gas into second tank 1020. Depending on the relative sizes
of first and second tanks 1010 and 1020 along with the set point
pressure to be achieved in the second tank 1020, valve 100 may need
to be reset by controller 2000 to again use exterior gas source 16
as suction for compressor 500 and the first tank 1010 as discharge,
in order to have enough gas to fill the second tank 1020 (or a
multiplicity of higher numbered staged tanks 1020, 1030, 1040,
1050, 1060, 1070, and 1080 such as by using a plurality of one way
check valves) to its predefined pressure set point for the second
compression stage.
Once the amount of gas pressure in the second tank 1020 has reached
the desired predefined pressure set point for tank 1020, valve 100
can be repositioned so that second tank 1020 becomes the suction
for compressor 500 and third tank 1030 receives discharge from
compressor 500. Because the gas in second tank 1020 is now at a
higher density and pressure compared to gas in first tank 1010,
compressor 500 now compresses additionally the higher density gas
into third tank 1020. Depending on the relative sizes of third and
second tanks 1030, 1020 along with the set pressure points to be
achieved in second and third tanks 1020 1030, valve 100 may need to
be reset by controller 2000 to again use first tank 1010 as suction
for compressor (relative to compressing into second tank), along
with using exterior gas source 16 as suction for compressor 500 and
the first tank 1010 as discharge, in order to have enough gas to
fill the third tank 1030 to its predefined pressure set point.
The above referenced staged compressing process is repeated through
as many staged pressurized tanks 1010, 1020, 1030, 1040, 1050,
1060, 1070, 1080, etc. as needed to reach the desired output
pressure of the highest numbered tank using the selected horsepower
of compressor 500. Unlike a multi-stage compressors, the same
compressor unit 500 and compressor chamber 570 can be used for each
stage of compressor (i.e., each differing suction and discharge
connections to compressor 500).
In one embodiment discharge from compressor 500 can be run through
a gas cooler 50 (not shown), where it can be cooled to
substantially ambient temperature at the outlet of gas cooler 50.
One embodiment can include a lubricant filter and separator 40. The
lubricant filter and separator 40 may comprise any of a number of
known filter-type devices adapted to remove lubricating oil or
liquids from a gas stream passing therethrough. The lubricant
filter and separator 40 functions to return compressor 500
lubricants to the suction 510 of compressor 500. Additionally,
since at ambient temperatures most gaseous fuels are capable of
containing vaporized or entrained lubricants or moisture, a
moisture-removing means may be included downstream of the lubricant
filter and separator 40. A properly sized and shaped lubricant
separator/filter 40 can substantially reduces the discharge
temperature of the gas while it separates the lubricant from the
gas. It is believed to accomplish this where the gas/lubricant
mixture is thrown at the separator walls (often in a cyclonic
action) which walls are cooler than the incoming gas. In addition,
because of the sizing of the compressor 500 and tanks 1000,
substantial cooling will occur as the gas is waiting for the next
stage to occur. Moisture removal is not shown in the schematic
drawings because moisture removal can be done at inlet line 16 in
this embodiment.
In another embodiment, where moisture and other condensables need
to be removed, means, well known to the art, will need to be used
at appropriate pressures for liquid removal.
FIG. 8 is a schematic diagram of a hermetically sealed single stage
compressor 500 with a piston 560 and cylinder compression chamber
570. In one embodiment compressor 500 can be used to compress a gas
into any of tanks 1010, 1020, 1030, 1040, 1050, 1060, 1070, or
1080. In one embodiment the input to compressor 500 can be changed
by controller 2000 from either an external source 16, or one of the
tanks in the tank array 1000.
In one embodiment a hermetically-sealed gas compressor 500 of
similar design to the types commonly employed in refrigeration
apparatuses can be used. One skilled in the art will readily
recognize, of course, that other compressors may alternatively be
used. Compressor 500 is schematically shown in FIG. 8 and can be a
hermitically sealed compressor having a housing or body 504 with
interior 506, input 510, output 520, motor 540, cylinder 550,
piston 560, and chamber 570. Chamber can have interior volume,
input 572, and output 574. Check valve 573 can be attached to input
572 of chamber 570. Check valve 575 can be attached to output 520.
Check valve 512 can be attached to compressor input 510. Check
valve 512 is used to prevent the high pressure gas energy built up
in the housing 504 from being lost as valve 100 cycles (such as
cycling to Position 1).
In one embodiment a sequencing valve 100 as described herein can be
used to operatively connect compressor 500 to tank array 1000. In
another one embodiment a plurality of valves in a manifold array
can be used to operatively connect compressor 500 to tank array
1000. In one embodiment controller 2000 can control sequencing
valve 100 or plurality of valves which operatively connect
compressor 500 to tank array 1000. In one embodiment pressure
sensors are provided at each of the tanks in tank array 1000 (tanks
1010, 1020, 1030, 1040, 1050, 1060, 1070, and 1080. Tanks 1010,
1020, 1030, 1040, 1050, 1060, 1070, and 1080) and real time
pressure data for each of the tanks are sent by such sensors to
controller 2000. With such information provided by pressure
sensors/transducers, controller 2000 operates compressor 500 and
sequencing valve 100 to control the flow of gas into (and out of)
each of the tanks in tank array 1000. Such control can be based on
a predefined set point for compressed gas in each of the tanks in
tank array 1000.
In one embodiment is provided a refueling system 10 along with
method of using the system 10 to refuel a vehicle 20 with
pressurized gaseous fuel. System 10 can be comprised of a gas
compressor 500 operatively connected to storage tank array 1000 by
a controller 2000. In one embodiment system 10 can switch sources
of gas to be compressed by compressor 500, and in one embodiment
tanks from tank array 100 into which compressor 500 had previously
discharged compressed gas, can in turn be used as the source of gas
to be further compressed by compressor 500 to another one of the
tanks in tank array 1000. In various embodiments this stacking or
layering of using the same compressor 500 to compress additionally
gas that compressor 500 had previously compressed can be repeated
limited only by the number of tanks in tank array 1000. In this
manner each tank can serve as a separate stage of compressor
ultimately increasing the possible maximum compressive output of
compressor 500 based on the number of different staged compressed
inputs.
In one embodiment system 10 can be used to deliver compressed
natural gas to a motor vehicle 20. Additionally, it is envisioned
that system 10 may be used to deliver compressed gas to devices
other than motor vehicles. For example, apparatus/system 10 can
deliver compressed gas to any storage tank, to a self-contained
breathing apparatus, a self-contained underwater breathing
apparatus, and like. Furthermore, as will be apparent to those
skilled in the art, the gas delivered need not be compressed
natural gas but may be other gases, e.g., be hydrogen, oxygen, air,
or any other compressible gas or fluid. For the sake of simplicity
of description, the remainder of this specification will refer to
the delivery of compressed natural gas, it being understood that
the system is applicable to the delivery of other compressible
fluids.
In one embodiment compressor 500 compresses the gaseous fuel, and
thereby increases its pressure to a predetermined desired pressure
level between tanks in tank array 1000. In one actually-constructed
prototype embodiment, such predetermined gas pressure is limited to
a 500 psi pressure differential between tanks in tank array 1000.
In one embodiment the following set pressure points are desired for
an eight tank array 1000.
TABLE-US-00002 Predefined Staged Predefined Staged Tank number High
Press Set Point (psi) Low Press Set Point(psi) T1 1010 150 150 T2
1020 650 350 T3 1030 1150 850 T4 1040 1650 1350 T5 1050 2150 1850
T6 1060 2650 2350 T7 1070 3150 2850 T8 1080 3650 --
For the initial fill process when each tank array 1000 is
essentially empty, compressor 500 pressurizes each tank (tanks
1010, 1020, 1030, 1040, 1050, 1060, 1070, and 1080) until a first
predetermined pressure (e.g., 150 psig) is reached in all tanks.
Once 150 psig is reached in each tank, valving is switched such
that the first tank 1010 will now serve as the compressor 500
suction tank. The compressor 500 depressurizes the first tank 1010
and pressurizes stages 2 through 8 (tanks 1020, 1030, 1040, 1050,
1060, 1070, and 1080) until the pressure in the first tank 1010
drops below a pressure predetermined first pressure drop (e.g., 50
psig). When the first tank 1010 drops below 100 psig valving is
switched such that the first tank 1010 will now be replenished by
the 0.5 psig domestic gas supply. Once the first tank 1010 is
re-pressurized to 150 psig using compressor 500, and valving is
switched again to make the first tank 1010 the compressor 500
suction tank to pressurize tanks 2 through 8 (tanks 1020, 1030,
1040, 1050, 1060, 1070, and 1080). This process is repeated many
times over until tanks 2 through 8 (tanks 1020, 1030, 1040, 1050,
1060, 1070, and 1080) reach a pressure of 650 psig.
Once tanks 2 through 8 (tanks 1020, 1030, 1040, 1050, 1060, 1070,
and 1080) reach a pressure of 650 psig, valving is switched such
that the second tank 1020 now serves as the compressor 500 suction
tank for pressurizing tanks 3 through 8 (tanks 1030, 1040, 1050,
1060, 1070, and 1080). Compressor 500 depressurizes the second tank
1020 and pressurizes tanks 3 through 8 (tanks 1030, 1040, 1050,
1060, 1070, and 1080) until the second tank 1020 drops below a
pressure predetermined first pressure drop (e.g., 350 psi). Once
the second tank 1020 drops below 320 psig, valving is switched such
that the first tank 1010 is now the compressor 500 suction tank and
the compressor 500 is pressurizing the second tank 1020 (only the
second tank because tank 3 is at a higher pressures than tank 2 at
this point and the check valve 1034 connecting tanks 2 and 3 blocks
flow until the pressure of tank 2 exceeds the pressure of tank 3).
Several similar cycles of depleting the first tank 1010 to
pressurize the second tank 1020 (and refilling the first tank 1010
with the domestic gas supply) will occur to bring the second tank
1020 back up to a pressure of 650 psig which is the first
predefined pressure for the second tank. Once the second tank 1020
achieves a pressure of 650 psig, valving is switched again to make
the second tank 1020 the compressor 500 suction tank for
pressurizing tanks 3 through 8 (tanks 1030, 1040, 1050, 1060, 1070,
and 1080) as the compressor discharge tanks.
Generally the above specified pattern can be repeated up through
tank 8 with each lower tank serving as the compressor suction tank
once their respective predefined pressure set point value is
achieved. Upon the tank pressure dropping below the predefined
lower tank value is reached when using a tank as a suction tank for
compressor 500, valving is switched to make lower tanks replenish
the upper tank. A more detailed method of preparing tank array 1000
is provided below.
Filling Vehicle Tank
Discharge of Gas into Car
In order to discharge gaseous fuel from system 10 into the vehicle
storage system 22, the outlet 14 is connected to the vehicle
storage system 22, valves 528 and 532 are opened, and valve 524 is
closed to minimize backflow through compressor 500. It is noted
that when valve 100's second port 260 is fluidly connected to a
chosen selector port of first family 109, second selector port 270
from valve 100 is also fluidly connected with a different selector
port from first family of ports. As the suction line of compressor
500 is fluidly connected to tanks of staged tank array 100 of
increasingly higher pressures, then such increasingly higher
pressures can be used as starting pressures to compress above and
beyond as such suction pressure fills interior 506 of housing
504.
In a default setting system 10 first fluidly connects first tank
1010 to outlet 14. The pressure of first tank 1010 is monitored for
a predetermined period of time to determine whether a transient
decrease in tank pressure is seen or pressure has entered a static
condition. After no change in pressure of first tank 1010 is seen
for a predetermined period of time, system 10 next fluidly connects
second tank 1020 to outlet 14. The pressure of second tank 1020 is
monitored for a predetermined period of time to determine whether a
decrease in tank pressure is seen or pressure has equalized. After
no change in pressure of second tank 1020 is seen for a
predetermined period of time, system 10 next fluidly connects third
tank 1030 to outlet 14. The pressure of third tank 1030 is
monitored for a predetermined period of time to determine whether a
decrease in tank pressure is seen or pressure has equalized. After
no change in pressure of third tank 1030 is seen for a
predetermined period of time, system 10 next fluidly connects
fourth tank 1040 to outlet 14. The pressure of fourth tank 1040 is
monitored for a predetermined period of time to determine whether a
decrease in tank pressure is seen or pressure has equalized. After
no change in pressure of fourth tank 1040 is seen for a
predetermined period of time, system 10 next fluidly connects fifth
tank 1050 to outlet 14. The pressure of fifth tank 1050 is
monitored for a predetermined period of time to determine whether a
decrease in tank pressure is seen or pressure has equalized. After
no change in pressure of fifth tank 1050 is seen for a
predetermined period of time, system 10 next fluidly connects sixth
tank 1060 to outlet 14. The pressure of sixth tank 1060 is
monitored for a predetermined period of time to determine whether a
decrease in tank pressure is seen or pressure has equalized. After
no change in pressure of sixth tank 1060 is seen for a
predetermined period of time, system 10 next fluidly connects
seventh tank 1070 to outlet 14. The pressure of seventh tank 1070
is monitored for a predetermined period of time to determine
whether a decrease in tank pressure is seen or pressure has
equalized. After no change in pressure of seventh tank 1080 is seen
for a predetermined period of time, system 10 next fluidly connects
eight tank 1080 to outlet 14. The pressure of eighth tank 1080 is
monitored for a predetermined period of time to determine whether a
decrease in tank pressure is seen or pressure has equalized. After
no change in pressure of eighth tank 1080 is seen for a
predetermined period of time, system 10 enters a "topping off" mode
depending on the amount of extra compressed gas to be offloaded
into vehicle's tank 22.
Single Selecting Valve Embodiment
FIGS. 1-8 and 9-39 show one embodiment of a single selecting valve
100. Selecting valve 100 can be used to operatively connect suction
and discharge ports of compressor 500 to selected tanks the tank
array 1000 (with suction port also being connectable to exterior
gas source 16).
The number of ports in first family of ports 109 can be 4, 5, 6, 7,
8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, and/or 20 ports. In
various embodiments there can be a range of number of ports in
first family of ports 109 between any two of the above specified
numbers.
The number of ports in second family of ports 209 can be 2, 3, 4,
and/or 5. In various embodiments there can be a range of number of
ports in second family of ports 209 between any two of the above
specified numbers.
Generally, selecting valve 100 can include first family of
selectable ports 109 and second family of selectable ports 209,
wherein two of the ports from the second family of selectable ports
can be selected to be fluidly connected with two of the first
family of selectable ports 109. First family of ports 109 can
include a plurality of ports 101, 110, 120, 130, 140, 150, 160,
170, and 180. Second family of ports can include a plurality of
ports 260 and 270.
Generally, valve 100 can comprise top 400, selector 300, and body
200. Selector 300 can be rotatively connected to both top 400 and
body 200.
In one embodiment top 400 can include first family of ports 109,
and body 200 can include second family of ports 209.
FIG. 9 is a perspective view of multi family multi port selector
valve 100 which can be used to connect the suction 510 and
discharge 520 lines of the compressor 500 to selected different
suction source and selected different discharge from the compressor
500. FIG. 10 is a top view of valve 100. FIG. 11 is a sectional
view of valve 100 taken along the lines 11-11 shown in FIG. 10.
FIG. 12 is a sectional view of valve 100 taken along the lines
12-12 shown in FIG. 10.
FIG. 13 is a top exploded view of the valve 100 showing the three
main components: (1) top 400 with first family of selector porting
109 and check valve porting; (2) selector 300 with selector
porting; and body 200 with selector recess 200 and second family of
selector porting 209 or base porting.
FIG. 14 is a bottom exploded view of valve 100 showing the three
main components: (1) top with selector and check valve porting; (2)
selector with selector porting; and body with selector recess and
base porting.
FIG. 15 is a side view of the top of the valve 100 showing both the
lower selector porting (first family 109 of selector porting) and
the upper check valve porting with check valves being omitted from
the check valve porting (and with only seven selector ports 101,
110, 120, 130, 140, 150 and 160 included in this version ease of
discussion).
FIG. 16 is a translucent top view of the top 400 of valve 100
showing both the lower selector porting (first family 109 of
selector porting) and the upper check valve porting (and with only
seven selector ports 101, 110, 120, 130, 140, 150 and 160 included
in this version ease of discussion).
FIGS. 16 and 17 include representative diagrams of a check valve
port 1024 with a check valve included in the port. Those skilled in
the art will recognize that the check valve 1024 can comprise ball
1260 and spring 1270 components. Spring 1270 will push ball 1260 in
the direction of arrow 1220 blocking flow in check valve 1024 in
the direction of arrow 1220 because gas attempting to flow in the
direction of arrow 1220 will be blocked by ball 1260 sealing the
port for flow going past ball 1260, while gas attempting to flow in
the direction of arrow 1210 will place a force on ball 1260 and, if
enough force on ball 1260 is seen, move both ball 1260 and spring
1270 in the direction of arrow 1210, and allow flow in the
direction of arrow 1240 until spring 1270 overcomes such gaseous
force and pushes back ball 1270 to seal the port.
FIG. 18 includes various views of the exploded valve 100 (and with
only seven selector ports 101, 110, 120, 130, 140, 150, and 160 of
the first family 109 included in this version for drawing clarity
and ease of discussion). Several of the cutaway views in FIG. 18,
while not technically correct have been edited for clarity of
presentation. Rather than mirror port and check valve cutaways as
is shown by the direction arrows, they are oriented the same way
for ease of understanding. The cutaway of the selector spool 300
doesn't exist as a flat plane but are showing together in the same
page to make clearer the simultaneous fluid connections conduits
360 and 370 and first and second selector ports 260 and 270 of the
second family of ports 209.
In one embodiment valve 100 can be operated to select a plurality
of ports from the first family 109 to be fluidly connected with a
plurality of ports with the second family 209, and such selected
plurality of ports from the first 109 and second 209 families to be
fluidly connected to each other can be changed by operation of the
valve 100.
As best seen in FIGS. 11, 12, and 18, selector 300 can be used to
select which ports from the first family of ports 109 will be
selectively connected to which ports of the second family of ports
209. Valve 100 in this embodiment includes a second family of ports
209 having two ports 260, 270 which are selectively connected to a
selected two of the first family of ports 109. That is, valve 100
allows two ports of the first family 109 to be connected to a
selected two ports of the second family 209.
To operate as a port selector between the first 109 and second 209
family of ports, selector 300 includes two selector conduits--first
conduit 360 and second conduit 370. In this embodiment, regardless
of the position of selector 300, first selector conduit 360 remains
fluidly connected to first port 260 of second family of ports 209,
however, first selector conduit 360 can be selectively connected to
a selected one of the first family of ports 109 (e.g., port 101,
110, 120, 130, 140, 150, 160, 170, and/or 180). In this embodiment,
regardless of the position of selector 300, second selector conduit
370 remains fluidly connected to second port 270 of second family
of ports 209, however, second selector conduit 370 can be
selectively connected to a selected one of the first family of
ports 109 (e.g., port 101, 110, 120, 130, 140, 150, 160, 170,
and/or 180). Selection of what port from the first family of ports
109 first selector conduit 260 is connected to and what port from
the first family of ports 109 second selector conduit 270 is
connected to can be controlled by rotation of selector 300 relative
to top 400.
In this embodiment, which pair of ports from the first family of
ports 109 is connected to first 360 and second 370 conduits of
selector 300 is dependent on the spaced geometry of upper/first
connector 362 of first conduit compared to upper/first connector
372 of second conduit in relation to the geometry of second
connectors (106, 116, 126, 136, 146, 156, 166, 176, 186) of first
family of ports 109 (101, 110, 120, 130, 140, 150, 160, 170,
180).
As best shown by FIG. 31 first connectors (362 and 372) of first
and second conduits (360 and 370) can be spaced about a circle
centered around the rotational axis 304 between selector 300 and
top 400 with an angular spacing of angle 380. Similarly, as best
shown by FIGS. 22A and 22B, second connectors (106, 116, 126, 136,
146, 156, 166, 176, 186) of first family of ports 109 (101, 110,
120, 130, 140, 150, 160, 170, 180) can likewise be symmetrically
spaced about a circle centered around the rotational axis 304
between selector 300 and top 400. The symmetrical spacing is
schematically indicated by double arrows 107, 117, 127, 137, 147,
157, 167, 177, 187', and 187'' wherein the angles 107, 117, 127,
137, 147, 157, 167, and 177 are equal to each other to obtain
symmetry. The angular spacing 380 can be an integer multiple of the
angular spacing between second connectors (106, 116, 126, 136, 146,
156, 166, 176, 186) of first family of ports 109 (101, 110, 120,
130, 140, 150, 160, 170, 180); wherein the integer can be 1, 2, 3,
4, 5, 6, 7, 8, 9, and/or 10 (or any range between any two of these
integers). Port 000 is labeled only as a dead port and will not
allow gas flow.
As disclosed in this embodiment angle 380 is equal to the angular
spacing between second connectors (106, 116, 126, 136, 146, 156,
166, 176, 186) of first family of ports 109 (101, 110, 120, 130,
140, 150, 160, 170, 180). With an equal spacing (i.e., integer
multiple of 1), first and second conduits 360 and 370 can only be
fluidly connected with adjacent ports of the first family of ports
109 (and therefore first and second ports 260 and 270 of the second
family of ports can only be fluidly connected to adjacent ports of
the first family of ports 109). The following table provides
examples of fluid port connections between first family 109,
selector conduits, and second family of ports 209.
On the other hand if the integer multiplier is 2 (angle 380 is
twice the size of the angles between second connectors (106, 116,
126, 136, 146, 156, 166, 176, 186) of first family of ports 109
(101, 110, 120, 130, 140, 150, 160, 170, 180), then first and
second conduits 360 and 370 can only be fluidly connected with one
port skipped adjacent ports of the first family of ports 109 (and
therefore first and second ports 260 and 270 of the second family
of ports can only be fluidly connected to one port skipped adjacent
ports of the first family of ports 109)
The numbers of ports in first family of ports 209 can be varied to
provide a user with the desired number of ports from which to
select fluid connections with. However, the angular spacing between
the second connectors (e.g., angular spacing 117 between second
connectors 106 and 116 of ports 101 and 110 should be equal to the
angular spacing 127 between second connectors 116 and 126 of ports
110 and 120 should be equal to the angular spacing, 126, etc.)
should remain equal, and such angular spacing should be an integer
multiple of the angular spacing between first connectors 362 and
372 of first and second conduits 360 and 370 of selector 300. Such
a construction allows selected fluid connection between selected
plurality of ports in the first family 109 with a selected
plurality of ports in the second family 209.
Below is a table listing various examples of selected fluid
connection between selected plurality of ports in the first family
109 with a selected plurality of ports in the second family
209.
Each row shows the fluid port connections for a selected position
or option with respect to valve 100. The listed Positions and first
and second selector port family connections are also shown
schematically in FIG. 1A.
TABLE-US-00003 TABLE 1 Listing of Selected Port Fluid Connections
Options: Position 1st Family Selector 300 2nd Family Selected 109
Ports Fluid Connection 209 Ports 1 101 370 270 110 360 260 2 110
370 270 120 360 260 3 120 370 270 130 360 260 4 130 370 270 140 360
260 5 140 370 270 150 360 260 6 150 370 270 160 360 260 7 160 370
270 170 360 260 8 170 370 270 180 360 260 9 180 370 270
With the above Table 1, it should be noted that, even with stage
changes, the fluid connections between selector conduits 360 and
370 and the second family of ports 260 remain the same. That is
regardless of the position of selector relative to valve, first
conduit 360 of selector 300 remains fluidly connected with first
port 260 of second family of ports 209, and second conduit 370 of
selector 300 remains fluidly connected with second port 270 of
second family of ports 209.
In one embodiment rotation of selector 300 selects which plurality
of ports from first family 109 are fluidly connected with which
plurality of ports from second family 209.
In the preferred embodiment first plurality of ports 109 can be
included in top 400, and second family of ports 209 can be included
in bottom. In an alternative embodiment first family or ports 109'
can be included in body 200 as well as second family of ports 209
(this is schematically shown in FIG. 40). In other embodiments
first family of ports 109 can be partly located in top 400 and
partly located in body 200. In other embodiments (not shown) it is
envisioned that first family of ports 109 and second family of
ports 209 can be located in top 400 (although such is not preferred
as it would complicate the construction and fabrication of top 400
and operation of valve 100).
The individual components of this embodiment of selector valve 100
will not be reviewed.
Top
FIGS. 19 and 20 are respectively top and bottom perspective views
of the top portion 400 of valve 100 showing selector first family
109 and check valve porting. FIGS. 21 and 22 (22A and 22B) are
respectively top and bottom views of top portion 400.
Top 400 can include upper portion 410, lower portion 420, and outer
periphery 414 thereby being cylindrical in shape. Top 400 can also
include a plurality of connector openings 404 which can be used to
connect top 400 to valve 100 (e.g., by body 200 as schematically
indicated in FIG. 18). The shape of top 400 does not have to be
cylindrical and other shapes are contemplated. It is only the
circular pattern of second connectors (e.g., 106, 116, 126, 136,
146, 156, 166, 176, etc.) that is required in order to match up
with first connectors 362 and 372 of first and second conduits 360
and 370 of selector that need to match up to provide that ability
to select between first 109 and second 209 families of ports for
fluid connection.
Top 400 can also include opening 420 for rod 314 of selector 300
which will control the rotational axis 304 between selector 300 and
valve 100.
Generally, top 400 includes a plurality of selector porting 430
which includes the first family 109 of selector ports. FIG. 23 is a
side view of the top portion 400. FIG. 24 is a sectional view taken
along the lines 24-24 of FIG. 23. Generally, in this embodiment top
400 has two sets of porting: (1) selector porting for the first
family of ports 109 and (2) check valve porting which can be used
to provide secondary fluid connection between specific selector
ports of the first family of ports 109.
As shown in the embodiment of FIG. 24, eight selector ports are
shown which include zero selector port 101 having first 102 and
second 106 connectors; first selector port 110 having first 112 and
second 116 connectors; second selector port 120 having first 122
and second 126 connectors; third selector port 130 having first 132
and second 136 connectors; fourth selector port 140 having first
142 and second 146 connectors; fifth selector port 150 having first
152 and second 156 connectors; sixth selector port 160 having first
162 and second 166 connectors; and seventh selector port 170 having
first 172 and second 176 connectors. As noted previously, the
angular spacing between radially adjacent second connectors of
selector porting should be equal, and angles 117, 127, 137, 147,
157, 167, and 167 should be equal. The angle between ports second
connectors 106 of zero port 101 and second connector 176 of seventh
port 170 does not have to be equal to the other angular spacing as
this is dead space where the first connectors 362 and 366 of
selector 300 moving in such dead space area will not be fluidly
connected to any of the selector ports of the first family 109 of
selector porting. However, as discussed elsewhere, regardless of
the position of selector 300, first and second conduits 360 and 370
remain fluidly connected respectively with first and second ports
260 and 270 of the second family of selector porting 209.
FIG. 15 is a side view of the top of the valve 100 showing both the
lower selector porting (first family 109 of selector porting) and
the upper check valve porting with check valves being omitted from
the check valve porting (and with only seven selector ports 101,
110, 120, 130, 140, 150 and 160 included in this version ease of
discussion). FIG. 16 is a top view of the top 400 of valve 100
showing both the lower selector porting (first family 109 of
selector porting) and the upper check valve porting with check
valves being omitted from the check valve porting (and with only
seven selector ports 101, 110, 120, 130, 140, 150 and 160 included
in this version ease of discussion).
FIG. 25 is a sectional view taken along the lines 25-25 of FIG. 23
(but with check valves omitted for clarity). FIG. 26 is a sectional
view taken along the lines 25-25, but with check valves
included.
Generally, top 400 can also include a plurality of alternative flow
check valve porting 450 which, regardless of the position chosen
for selector 300 relative to valve 100, check valve porting 450
fluidly connects individual pairs of ports in the first family 109
of selector ports for fluid flow in a first direction as long as
pressure between the connected ports exceeds the pressure required
to overcome the check valve closing action, but does not allow
fluid flow in a second direction, which is opposite to the first
direction between the connected ports regardless of differential
pressures between selector ports. In one embodiment adjacent
selector porting of the first family 109 of ports can be chained
via check valve porting to fluidly connect more than single pairs
of first family ports.
As shown in the embodiment of FIGS. 24-26, seven check valve ports
are shown which include check valve port 1014' having first 1015
and second 1016 ends (between zero selector port 101 and first
selector port 110); check valve port 1024' having first 1025 and
second 1026 ends (between first selector port 110 and second
selector port 120); check valve port 1024' having first 1025 and
second 1026 ends (between second selector port 120 and third
selector port 130); check valve port 1044' having first 1415 and
second 1046 ends (between third selector port 130 and fourth
selector port 140); check valve port 1054' having first 1055 and
second 1056 ends (between fourth selector port 140 and fifth
selector port 150); check valve port 1064' having first 1065 and
second 1066 ends (between fifth selector port 150 and sixth
selector port 160); check valve port 1074' having first 1075 and
second 1076 ends (between sixth selector port 160 and seventh
selector port 170).
FIGS. 25 and 26 show the use of check valve porting to fluidly
connect various ports in the first family of selector ports 109.
Zero port 101 can be fluidly connected to first port 110 in a first
direction (i.e., from zero port 101 to first port 110) through
check valve porting 1014'. First port 110 can be fluidly connected
to second port 120 in a first direction (i.e., from first port 110
to second port 120) through check valve porting 1024'. Second port
120 can be fluidly connected to third port 130 in a first direction
(i.e., from second port 120 to second port 130) through check valve
porting 1034'. Third port 130 can be fluidly connected to fourth
port 140 in a first direction (i.e., from third port 130 to fourth
port 140) through check valve porting 1424'. Fourth port 140 can be
fluidly connected to fifth port 150 in a first direction (i.e.,
from fourth port 140 to fifth port 150) through check valve porting
1054'. Fifth port 150 can be fluidly connected to sixth port 160 in
a first direction (i.e., from fifth port 150 to sixth port 160)
through check valve porting 1064'. Sixth port 160 can be fluidly
connected to seventh port 170 in a first direction (i.e., from
sixth port 160 to seventh port 170) through check valve porting
1074'.
In each of the above check valve porting connections gas can flow
in a first direction as explained, but gas is prevented from
flowing in a second direction (which is the opposite of the first
direction) via the applicable check valve porting: (1) via check
valve porting 1014' from first port 110 to zero port 101; (2) via
check valve porting 1024' from second port 120 to port 110; (3) via
check valve porting 1034' from second port 120 to second port 130;
(4) via check valve porting 1044'. from fourth port 140 to third
port 130; (5) via check valve porting 1044' from fifth port 150 to
fourth port 140; (6) via check valve porting 1054' from sixth port
160 to fifth port 150; and (7) via check valve porting 1064' from
seventh port 170 to seventh port 170.
Although not shown in this embodiment, top 400 can include an
eighth selector port 180, and seventh port 170 can be fluidly
connected to eighth port 180 in a first direction (i.e., from
seventh port 170 to eighth port 180) through check valve porting
1084'. An eight selector port 180 would allow valve 100 to be used
with the seven tank embodiment disclosed in FIGS. 1 and 2.
Selector
FIGS. 27 and 28 are respectively top and bottom perspective views
of one embodiment of selector 300. FIGS. 29 and 30 are respectively
is a side and bottom views of selector 300. FIG. 31 is a top view
of selector 300 with FIG. 36 being a sectional view taken along the
lines 32-32, and FIG. 33 being a sectional view taken along the
lines 33-33.
Selector 300 generally can include upper 310 and lower 320 portions
with an outer periphery 330 between upper 310 and lower 320
portions, along with rod 314 being attached to upper 310 section
(shown in FIG. 12). Selector 300 can have a rotational axis 304.
Arrow 316 schematically indicates relative rotation between
selector 300 and top 400/body 200 in a clockwise direction.
Between upper 310 and lower 320 portions can be first 360 and
second 370 conduits. First conduit 360 can include first connector
362 which opens onto upper portion 310 and second connector 366
which opens onto lower 320 portion. Second conduit 370 can include
first connector 372 which opens onto upper portion 310 and second
connector 372 which opens onto lower 320 portion.
Lower portion 320 can include annular recess 390 which fluidly
connects with second conduct 370.
Lower portion 320 can also include trunnion connector 324 which
will sit in trunnion recess 240 of body 200. Second connector 366
can open from lower portion of trunnion 324.
To maintain a seal between selector 300 and body 200 seal recess
323 and 325 along with seal components such as o-rings or other
conventionally available sealing can be included. To maintain a
seal between selector 300 and top 400 seal recess 321 and 322 along
with seal components such as o-rings or other conventionally
available sealing can be included.
Sealing in recess 325 can fluidly seal the connection between first
conduit 360 and first selector port 260 of the second family of
porting 209. Both sealing in recess 323 and recess 325 can fluidly
seal the connection between second conduit 370 and second selector
port 270 of the second family of porting 209.
Between first connector 362 of first conduit 360 and first
connector 372 of second conduit 370 can be angle 380 which as
stated elsewhere is preferably equal to the angular spacing between
second connectors of the first family of selector ports 109.
Conventionally available sealing can be used for effecting a seal
between first connector 362 of first conduit 360 and its selected
port of the first family of ports 109, along with first connector
372 of second conduit 370 and its selected port of the first family
of ports 109
By controlling the angular spacing 380 of the first connectors 362
and 372 relative to the angular spacing for the second connectors
of the first family of selecting ports 109, relative connections
between the first family of selector ports 109 and the second
family of selector ports 209 can be controlled varied. For example,
if the angular spacing 380 is the same then adjacent second
connectors of the first family of selector ports 109 will be
fluidly connected with the second family of selector ports 209. If
the relative angular spacing is 2, then spaced apart second
openings of the first family of selector ports 109 will be fluidly
connected to the second family of selector ports 209. If the
spacing is 3 times, then twice spaced apart second openings of the
first family of selector ports 109 will be fluidly connected to the
second family of selector ports 209. For each multiple of spacing
the formula of [multiple-1]*spaced apart second openings of the
first family of selector ports 109 will be fluidly connected to the
second family of selector ports 209. In the case of 1-1, then no
spaced apart connections are made, but adjacent second openings of
the first family of selector ports 109 will be fluidly connected to
the second family of selector ports 209.
Body
FIGS. 34 and 35 are respectively top and bottom perspective views
of one embodiment of body 200. FIGS. 36 and 37 are respectively
side and bottom views of body 200. FIG. 38 is a top view of body
200 with FIG. 39 being a sectional view of body 200 taken along the
lines 39-39.
Body 200 generally can include upper 210 and lower 220 portions
with an outer periphery 214 between upper 210 and lower 220
portions, along with a selector recess 220 for rotationally
attaching selector to body 200. Base 224 of recess 240 can also
include trunnion recess 240 for rotationally connecting trunnion
324 of selector 300. With rotational connection selector 300 and
body have a rotational axis 304. Arrow 316 schematically indicates
relative rotation between selector 300 and top 400/body 200 in a
clockwise direction.
Between base 224 of recess 220 and lower 220 portion can be first
260 and second 270 selector ports. First selector port 260 can
include first connector 262 which opens into the bottom of trunnion
recess 240 and second connector 266 which opens into lower 220
portion. Second selector port 270 can include first connector 272
which opens into base 224 of recess 240 and second connector 272
which opens into lower 220 portion.
To maintain a seal between body 200 and top 400 annual seal 216
with seal components such as o-rings or other conventionally
available sealing can be included. In one embodiment annular seal
216 can be used to seal porting drill holes made for either check
valve porting and/or selector porting of the first family of
selector ports 109 in top 400. In other embodiments the extraneous
drilling porting can be backfilled or sealed in other manner
conventionally available.
Alternative Valve Constructions
FIG. 40 is a schematic diagram of another embodiment of a selecting
valve 100' which is modified from the construction of the valve 100
shown in FIG. 9 by having the selector porting of the first family
of selector ports 109 (e.g., 101', 110', 120', 130', 140', etc.)
located in lower body 200 portion instead of the upper top 400. The
second family of selector porting 209 can be substantially the same
as in other embodiments. In this embodiment, the first 360 and
second 370 selector conduits have first 362 and second 372
connectors which open into the outer periphery 330 of selector 300
instead of top 310.
In this alternative valve 100' check valve porting (e.g., 1014',
1024', 1034', 1044', 1054', 1064', 1074', etc.) is also located in
and in lower body 200 portion instead of the upper top 400, and the
check valve porting will similarly provide one way fluid paths
between adjacent selector ports of the first family of selector
porting 109'.
FIG. 41 shows one embodiment of a sealing mechanism between
selector 300 and the selector porting of the first family of
selector porting 109' located in body 200 (e.g., FIG. 40). Similar
sealing can be used for sealing when selector porting of the first
family 109 is located in the top 400 (e.g., FIG. 9). This sealing
embodiment has a two sealing members which are biased towards each
other.
FIG. 42 shows alternative selector 300 porting having two first
conduits 360 and 360' with first connectors 362 and 362', along
with two second conduits 370 and 370' each having first connectors
372 and 372'. The angular spacing between first connectors 362 and
362' along with first connectors 372 and 372' should be equal and
the angular spacing between the pair of first conduits 360, 360'
and pair of second conduits 370,370' should be double the spacing
between individual connectors.
FIG. 43 includes various embodiments of high pressure tubing
connections 1300 which can be used with one or more embodiments
disclosed in this application. The high pressure tubing connection
can include threaded connector 1310 with softer sealing element
1320. Softer sealing element 1320 is preferably made of teflon or
some other material that is softer than flared tubing 1330. Sealing
element 1320 can be placed in cavity 1340. Sealing element 1320 can
be placed in cavity 1340 and can be easily replaced if damaged.
This sealing design has the added advantage of being simple to
mechanically produce. Those skilled in the art only need to drill
them tap the cavity but not all the way to the bottom of the hole.
This creates a sealing surface beyond the length of the threads for
sealing element 1320 to press against. This design has the added
advantage of creating a smooth internal bore between the cavity and
the flared tubing as seen in the bottom illustration of the elbow.
This design has the added advantage of compactness because it does
not require the use of a conventional adapter fitting which usually
leaves a gap at the bottom of the cavity. That gap causes
turbulence during high speed gas flow which creates thermal shock
to the conventional fitting, eventually causing it to leak.
Valve Embodiments
In one embodiment is provided a selecting valve 100 having a first
family of ports 109 having a plurality of ports (e.g., 101, 110,
120, 130, 140, 150, 160, 170, and/or 170) and a second family of
ports 209 having a plurality of ports (e.g., 260 and 270), at
selected option of a user a plurality of ports from the first
family of ports being selectively fluidly connectable with a
plurality of ports of the second family of ports 209.
In one embodiment the first family 109 has a plurality of ports. In
one embodiment the first family 109 has 2, 3, 4, 5, 6, 7, 8, 9, 10,
11, 12, 13, 14, 15, 16, 17, 18, 19, and 20 ports. In various
embodiments the first family of ports 109 has between any two of
the above specified number of ports.
In one embodiment the second family of ports 209 has a plurality of
ports. In one embodiment the second family has 2, 3, 4, 5, 6, 7, 8,
9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, and 20 ports. In various
embodiments the second family of ports 209 has between any two of
the above specified number of ports.
In one embodiment the first family of ports 109 has two ports and
the second family of ports 209 has 4, 5, 6, 7, 8, 9, 10, 11, 12,
13, 14, 15, 16, 17, 18, 19, and 20 ports. In various embodiments
the first family of ports 109 has two ports and the second family
of ports 209 has between any two of the above specified number of
ports.
In one embodiment the second family of ports 209 can be fluidly
connected in a first direction by a plurality of one way valves
(e.g., 1014, 1024, 1034, 1044, 1054, 1064, 1074, and 1084). In one
embodiment the one way valves can be a plurality of check valves.
In one embodiment the plurality of check valves can be ported in
the top 400 of the valve 100. In one embodiment the plurality of
check valves can be ported in the body 200 of the valve 100.
In one embodiment a selector 300 can be operatively connected to
the first 109 and second family 209 of ports and used to
selectively fluidly connect a first selected selector port (e.g.,
port 101) from the first family 109 to a first selected first port
(e.g., port 270) from the second family 209, and a first selected
second selector port (e.g., port 110) from the first family 109 to
a first selected second selector port (e.g., port 260) from the
second family 209. In one embodiment the selector 300 can be used
to change the earlier selected connections between the first 109
and second 209 family of selector ports, to selectively fluidly
change to a second selected selector port (e.g., port 110) from the
first family 109 to a selector port (e.g., port 270) from the
second family 209, and a second selected second port (e.g., port
120) from the first family 109 to a second selector port (e.g.,
port 260) from the second family 209. In such a manner selector 300
can be used to selectively change the selected connections between
a plurality of selector ports from the first family of selector
ports 109 to a plurality of selector ports from the second family
of selector ports 209.
In one embodiment the selector 300 is used to selectively switch
the fluid connection between the first port from the first family
109 and the first port from the second family 209 to the first port
from the first family 109 to a third port from the second family
209, and from the second port from the first family 109 to a fourth
port from the second family 209.
In one embodiment is provided a selecting valve 100 comprising a
body 200 having a first family of ports 109 having a plurality of
ports (e.g., 101, 110, 120, 130, 140, 150, 160, 170, and 180) and a
second family of ports 209 having a plurality of ports (e.g., 260
and 270), and a selector 300 rotatably mounted with respect to the
body 200, the selector 300 selectively fluidly connecting a first
port from the first family 109 to a first port from the second
family 209 and a second port from the first family 109 to a second
port from the second family 209, where the first and second ports
in the first family 109 are different ports, and the first and
second ports in the second family 209 are different ports.
In one embodiment rotation of the selector 300 relative to the body
200 (e.g., in the direction of arrow 316) selectively switches the
fluid connections between a first port from the first family 209
(and the first port from the second family 209) and a second port
209 from the first family 109 (and the second port from the second
family 209) to fluidly connecting the first port from the first
family 209 to a third port from the second family 209, and fluidly
connecting the second port from the first family to a fourth port
from the second family 209.
In one embodiment the selector 300 has a circular cross section and
is rotationally connected to the body 200. In one embodiment the
selector 300 has a rotational axis 304 relative to the body 200. In
one embodiment the selector 300 has at least one trunnion 324 which
rotationally connects the selector 300 to the body 200.
In one embodiment the first port 260 of the second family 209
includes an opening which fluidly connects with the selector 300 at
the intersection of the rotational axis 304 of the selector 300
relative to the body 200. In one embodiment the second port 270 of
the second family includes a fluid connection with the selector 300
that is spaced apart from the rotational axis 304 of the selector
300 relative to the body 200. In one embodiment the fluid
connection between the selector 300 and the second port 270 of the
second family 209 includes an annular recess (e.g., 390 in selector
300 and/or 390' in body 200) the annular recess being circular with
its center aligned with the rotational axis 304 between the
selector 300 and the body 200. In one embodiment the annular recess
390 is in the selector 300. In one embodiment the annular recess
390' is in the body 200. In one embodiment mating annular recesses
390 and 390' are located in the selector 300 and the body 200.
In one embodiment the selector 300 includes first and second
selector fluid conduits (360 and 370), with the first selector
fluid conduit 360 having first 362 and second 366 port connectors
and the second selector fluid conduit 370 having first 372 and
second port 376 connectors.
In one embodiment the first family of ports 109 includes a
plurality of conduits (e.g., 101, 110, 120, 130, 140, 150, 160,
170, and 180) having first (e.g., 102, 112, 122, 132, 142, 152,
162, 172, and 182) and second connectors (e.g., 106, 116, 126, 136,
146, 156, 166, 176, and 186) with the second opening of each of the
ports being located on a circle having its center located on the
relative axis of rotation 304 between the selector 300 and the body
200, and with the angular spacing (e.g., 117, 127, 137, 147, 157,
167, 177, and 187) between adjacent second connectors (e.g., 106,
116, 126, 136, 146, 156, 166, 176, and 186) being the same, and the
selector 300 having first 360 and second 370 conduits each having
first and second connectors (first conduit 360 having first
connector 362 and second connector; and second conduit 370 having
first connector 372 and second connector 376), with the first
connectors 362 and 372 of the first 360 and second 370 conduits
being located on a circle having its center located on the relative
axis of rotation 304 between the selector 300 and the body 200, and
the angular spacing 380 between the first connectors 362 and 372 of
the first and second conduits 360 and 370 being a multiple of the
angular spacing between adjacent second openings of the second
family of ports 109. In one embodiment the angular spacing between
the first connectors 362 and 372 of the first 360 and second 370
conduits is the same as the angular spacing between adjacent second
openings of the first family of ports 109. In various embodiments
the multiple is 1, 2, 3, 4, 5, 6, 7, 8, 9, and/or 10. In various
embodiments the multiple a set of integers falling within a range
of any two of the above specified integers.
In one embodiment, regardless of the relative angular position
between the selector 300 and the body 200, the second port
connector 366 of the first selector conduit 360 of the selector 300
remains fluidly connected to the first port 260 of the second
family of ports 209. In one embodiment, regardless of the relative
angular position between the selector 300 and the body 200, the
second port connector 376 of the second selector conduit 300
remains fluidly connected to the second port 270 of the second
family of ports 209.
In one embodiment, regardless of the relative angular position
between the selector 300 and the body 200, the second port
connector 366 of the first selector conduit 360 of the selector 300
remains fluidly connected to the first port 260 of the second
family of ports 209; and the second port connector 376 of the
second selector conduit 300 remains fluidly connected to the second
port 270 of the second family of ports 209.
In one embodiment relative angular movement between the selector
300 and the body 20 causes one of the second port connectors (e.g.,
376) of the plurality of conduits (conduits 360 and 370) of the
selector 300 to move in an arc having a substantially uniform
radius of curvature about the axis of rotation 304 between the
selector 300 and the body 200. In one embodiment, relative angular
movement greater than 360 degrees causes one of the second port
connectors (e.g., 376) of the plurality of conduits (conduits 360
and 370) of the selector 300 to move in a circle having a radius,
while another second port connector (e.g., 366) of the first
selector conduit 360 rotates in a single spot about the rotational
axis 304 between the selector 300 and the body 200.
In one embodiment relative angular movement of the selector 300
with respect to body 200 causes a first selector port of the first
family of selector ports 109 to be connected to a first selector
port of the second family of selector ports 209 and a second
selector port of the first family of selector ports 109 to be
connected to a second selector port of the second family of
selector ports, where both the first and second selector ports of
the first family are different, and the first and second selector
ports of the second family are different.
In one embodiment, relative angular rotation of selector with
respect to body of less than the angular spacing between the
adjacent second openings of the first family of selector ports 109
causes the first and second conduits of the selector 300 to change
from being fluidly connected to being fluidly with the first family
of selector ports 109, but such conduits remain fluidly connected
with the second family of selector ports 209.
Below will be provided with various examples of system 10
performing steps in various embodiments of the method which
include: (A) initial filling of storage tank array 1000 with
compressed gaseous fuel; (B) using system 10 to fill a vehicle
(e.g., offloading); and (C) refreshing storage tank array 1000
after offloading to be ready for another fill. In this section the
term Work
Adjusted Volumetric Efficiency (WAVE) methodology will be used as a
general label for using a method and apparatus for compressing
gases in a staged method with recompressing at least part of the
same gas from a first storage medium, to a second storage medium,
to a third storage medium, and beyond wherein previously compressed
gas is used again as the suction gas in compressor 500 to compress
in second, third, etc. stages above the earlier stage's compression
pressure points. The storage media described in this embodiment
include storage tanks.
By using tanks of progressively higher staged pressures, a single
compressor 500 can be used to progressively compress gas to higher
and higher staged pressures notwithstanding the fact that the
maximum compression rating for such compressor is less than the
higher stage pressures. In fact, increasing the number of stages
can allow compressor 500 to multiply its effective maximum
compression because, with respect to each stage, the compressor
itself only sees the difference between its inlet/suction/source
pressure and outlet/discharge pressures.
General Overview of Initial Fill Process for System 10 with an
Eight Staged Tank System
This section will describe just a brief overview of system 10
(filling the storage tanks or other device/medium), using Work
Adjusted Volumetric Efficiency (WAVE) methodology for transferring
compressed gas into the storage medium (tanks) through the
compressor 500.
1. The described example fill process represents the initial
filling of the staged storage tank array 10. This type of fill
process is generally only accomplished one time since staged
storage tank array 10 will not be subsequently completely depleted.
It is believed that refilling the only partially depleted staged
storage tank array 1000 gains a great deal of system efficiency by
never fully depleting the system of the stored energy. It is also
believed that the ability of operating with a single very small
horse powered compressor 500, incrementally compressing multiple
tanks in a pressurized staged tank array (in essence simulating the
existence of other stages for a multiple staged compressor), will
increase compression efficiency as the number of stages increase in
the staged tank array 1000.
3. FIGS. 44-59 depict typical system Fill, Off-load and Refresh
Process WAVE methodologies of efficiently storing the gas at ever
increasing energy storage levels. This example represents the first
and only time system 10 needs to be completely filled. The
preferred embodiment of system 10 will generally not deplete the
tank gas volumes in staged pressurized tank array 1000; however
they could depending upon the need. These remaining system stored
energy-states (in staged pressures of tank array 1000 used as
suction sources for compressor 500) greatly benefit the subsequent
compression, storage and off-loading process system
efficiencies.
Initial System 10 Fill Process
Stage 1 WAVE Position 1
1. In this stage the first tank 1010 of the staged pressure tank
array 1000 will be filled by compressor 500 to a first predefined
set point pressure (SP1) of 150 psig. There currently is no
pressure (0 psi) in any of the tanks of storage tank array 1000,
compressor 500, tubing, or valves.
2. Ambient temperature exists for all components (conservatively
accepted to be 80 degrees F.). For the purposes of this method
description the pressure deltas across the valve's 100 internal
check valving and ports (e.g., check valves 1014, 1024, 1034, etc.)
is not accounted for in the text description so as to more easily
describe the subsequent pressure changes in the higher compressed
tank stages (such as between individual tanks 1010, 1020, 1030,
etc. in storage tank array). It is noted that prototype valve 100
internal check valves have a release spring delta pressure of 3 psi
each. Accordingly, as the disclosed Fill, Off-load, and/or Refresh
processes are described, the WAVE gas moving between staged tanks
1010, 1020, 1030, etc. through the one way valving (e.g., check
valves 1014, 1024, 1034, etc.) to the subsequent next higher staged
tanks will be 3 psi less for each subsequently higher staged
tank.
3. The source gas valve 17 between the external gas supply 16 is
opened and gas flows to zero port 101 of valve 100 and is routed
through first selector port 270 of second family of ports 209 into
compressor 500 hermetic housing 504.
4. Controller 2000 causes valve 100 to be initially rotated to the
first position for pressurizing staged tank array 1000 null
position (i.e., Position 1). A motor can be operatively connected
to stem 314 of valve 100 and operatively connected to controller
2000 allowing for selective positioning of selector 300 in valve
100, and thereby control which ports in first family ports 109 will
be fluidly connected to which ports in second family of ports 209.
In Position 1, selector port zero 101 of first family 109 is
connected to second selector port 270 of second family 209, and
first selector port 260 of second family 209 is connected to first
port 110 of first family. Because second selector port 270 of
second family is connected to inlet or suction 510 of compressor
500, inlet 16 at this stage will serve as the suction gas for
compressor 500. Because first selector port 270 of second family
209 is connector to outlet or discharge 520 of compressor, at this
stage first tank 1010 will receive the discharge of compressor
500.
Because check valves 1014, 1024, 1024, 1034, 1044, 1054, 1064,
1074, and 1084 respectively fluidly connect in a one way (e.g.,
increasing) direction tanks 1010, 1020, 1030, 1040, 1050, 1060,
1070, and 1080 to each other (tank 1010 to 1020, 1020 to 1030, 1030
to 1040, 1040 to 1050, 1050 to 1060, 1060 to 1070, and 1070 to
1080) allowing higher pressure gas to flow from lower numbered
staged tanks in tank array 1000 to higher numbered tanks assuming
that the minimum check valve activation pressure can be overcome at
this stage inlet gas 16, although primarily discharging to tank
1010 (through first port 110), compressor 500 discharge gas also
indirectly flows also to tanks 1020, 1030, 1040, 1050, 1060, 1070,
and 1080.
NOTE: The safety shutoffvalves (e.g., 1013, 1023, 1033, 1043, 1053,
1063, 1073, and 1083) to the storage tanks are operated
corresponding to the associated need for such valves to be
opened/closed and their particular operation, and are not further
discussed in this section.
5. Compressor 500 is turned on.
6. Time 0 minutes, temperature ambient--compressed gas begins to
flow from the Compressor 500 through line 520, through separator
40, through line 521, through valve 524, through valve 528, through
line 522, to second port 260 in the middle of the valve 100,
through selector 300, and as described above through each of the
internal check valves (1014, 1024, 1024, 1034, 1044, 1054, 1064,
1074, and 1084) since each of the higher numbered tanks (tank 1010
to 1020, 1020 to 1030, 1030 to 1040, 1040 to 1050, 1050 to 1060,
1060 to 1070, and 1070 to 1080 are at less pressure than its
connected lower numbered tank. In one embodiment, the charge gas
temperature for valve 100 never exceeds approximately 110 degrees
F.
7. The discharge gas from compressor 500 effluent enters each of
the eight tanks of storage tank array 1000 substantially
simultaneously. The pressure in storage tank array 1000 slowly and
uniformly rises from approximately 0 to 150 psig. Throughout this
range of pressure rise, the temperature of the gas within
compressor chamber 570 of compressor 500, compressor 500 structural
housing 504 and within the downstream tank array 1000, rises
proportionally related to the formula PV=nRT. NOTE: Due to the
nature of system 10 and its process, the latent heat of compression
can be substantially reduced by volumetric sizing of the system and
the process accomplishment speed. In various embodiments no added
external cooling is needed to lower the gas temperature back to
ambient. NOTE: In one embodiment compressor 500 has been optimally
designed for a horsepower to displacement to volumetric efficiency
to system tank size to system delivery rate, and to a system
recovery rate. Therefore in such optimized embodiment the single
stage compressor 500 is able to accomplish single stage compression
process steps, the work of a multi-stage compressor (e.g., an eight
stage compressor).
8. At approximately 8.3 hours the pressure in each of the tanks in
tank array 1000 has reached a system stage 1 set point pressure
stage 1(SP1) of 150 psig. Note: Tank 1010 of staged tank array 1000
is the first stage tank, and system 10 is now ready to proceed to
step two by pressurizing higher numbered staged pressure tanks
1020, 1030, 1040, 1050, 1060, 1070, and 1080 to the second
predefined staged set point pressure 2 (SP2) using the gas in the
first stage of operation (i.e., the compressed gas in first tank
1010 which was compressed to the first predefined staged pressure
SP1 which in this embodiment is 150 psig) and compressor 500 to
recompress gas to higher numbered tanks in tank array.
Stage 2 WAVE Position 2
9. In this stage the first tank 1010 in staged tank array 1000 will
be used as the suction source for compressor 500 in filling higher
stages of staged tank array 1000. Controller 2000 causes valve 100
to rotated from Position 1 to position two (i.e., Position 2). In
Position 2, first selector port 110 of first family 109 is
connected to second selector port 270 of second family 209, and
second selector port 260 of second family 209 is connected to
second port 120 of first family 109. Gas from tank 1010 at this
stage will serve as the suction gas for compressor 500, and second
tank 1020 will receive the discharge of compressor 500. Because
check valves 1024, 1034, 1044, 1054, 1064, 1074, and 1084
respectively fluidly connect in a one way (e.g., increasing)
direction tanks 1030, 1040, 1050, 1060, 1070, and 1080 to each
other (tank 1030 to 1040, 1040 to 1050, 1050 to 1060, 1060 to 1070,
and 1070 to 1080) allowing higher pressure gas to flow from lower
numbered tanks to higher numbered tanks assuming that the minimum
check valve activation pressure can be overcome) at this stage gas
from tank 1010, although primarily discharging to tank 1020
(through second port 110), Compressor 500 discharge gas also
indirectly flows also to tanks 1030, 1040, 1050, 1060, 1070, and
1080. Because tank 1020 is at a higher pressure than tank 1010,
check valve 1014 will prevent flow from tank 1020 to tank 1010.
Using both selector ports and check valve porting, Compressor 500
utilizes the 150 psig gas of tank 1010 to compress into tanks 1020,
1030, 1040, 1050, 1060, 1070, and 1080. Compressor 500 continues to
run until the pressure in tank 1010 drops to a predefined first
tank set point lower pressure (SP1.1) which in this embodiment can
be 100 psig. However, it should be noted that SP1.1 is
predetermined such that it can be the most efficient pressure
point, given the challenge system 10's compressor 500 to compress
with higher of a differential pressures. During this stage it is
noted that compressor 500 is hermetically sealed, and the rear of
piston 560 of compressor 500 sees the inlet pressure (i.e., the
pressure of being fed by tank 1010) and the discharge 520 sees the
pressure in tanks 1020, 1030, 1040, 1050, 1060, 1070, and 1080.
Accordingly, in this second stage when the pressure in tank 1010
drops to 100 psig the differential that compressor 500 is
attempting to compress over is equal to the back pressure of the
higher numbered tanks less than the pressure in the current suction
tank 1010.
It is noted that SP1.1 can also chosen so that the transferred gas'
temperature returns to ambient, the piston housing's 504 oil bath
temperature lowers because the compressor 500 is no longer
compressing at its higher horsepower loading.
10. Once tank 1010 reaches SP1.1, system 10 now proceeds back a
step to gain additional moles of gas to refill tank 1010 up to SP1.
Controller 2000 causes stem 314 of valve 100 to be rotated to
Position 1 and 0.5 psig is waiting at port zero 101.
11. Compressor 500 is now taking gas from inlet 16 at 0.5 psig and
compressing this gas against the 100 psig in tank 1010 until the
pressure of tank 1010 rises above the pressure seen in tank 1020
(and higher numbered tanks in tank array 1000 via one way check
valves). The gas exiting compressor 500 is approximately 110
degrees F., and quickly cools to 70 degrees as it expands into the
tanks. Compressor 500 uses inlet 16 gas at 0.5 psig to again fill
tank 1010 with compressed gas at SP1 of 150 psig, and then
controller 2000 moves valve 100 to Position 2 to cause tank 1010 to
be the suction for compressor 500 when compressing gas as described
in step 9.
12. The repeating process of: (a) using tank 1010 as the suction
gas source for compressor 500 when compressing to higher staged
tanks in tank array 1000 (tanks 1020, 1030, 1040, 1050, 1060, 1070,
and 1080) until the pressure of now source tank 1010 SP1.1 drops to
100 psig; and then (b) switching valve 100 to Position 1 where home
source 16 becomes the suction pressure source for compressor 500
and tank 1010 becomes the discharge until tank 1010 is refilled to
its SP1 pressure of 150 psig: and then (c) switching valve 100 to
Position 2 where tank 1010 is again the suction source for
compressor 500 to compress gas to higher staged tanks in tank array
1000 until the next staged tank 1020 in tank array 1000 reaches a
desired staged set point pressure (SP2) of 650 psig.
It takes about 22.5 minutes for compressor 500 to use home source
16 to fill first tank 1010 to its SP1 pressure of 150 psi.,
repeating steps 9(a), (b), and (c) are repeated 63 times, at an
approximate rate of 22.5 minutes per (a) to (c) step, and the
entire time line for bringing the next staged tank 1020 in tank
array 1000 to desired staged set point pressure (SP2) of 650 psig
takes approximately 23.7 hours to complete, for a cumulative time
period for compression Stage 1 and Stage 2 run-time is about 32
hours. Now, when SP1 of 650 psig is achieved in tank 1020, and
system 10 is ready to move from Stage 2 to Stage 3, the actual
pressure in first staged tank 1010 will be somewhere between its
predefined SP1 of 150 psig and predefined lower SP1.1 of 100
psig.
Stage 3 WAVE Position 3
13. Valve 100 is rotated to Position 3. In this stage the second
tank 1020 in staged tank array 1000 will be used as the suction
source for compressor 500 in filling higher stages of staged tank
array 1000 to a third predefined staged pressure set point (SP3)
which in this embodiment is 1,150 psig. Controller 2000 causes
valve 100 to be rotated to position three (i.e., Position 3). In
Position 3, second selector port 120 of first family 109 is
connected to second selector port 270 of second family 209, and
selector port 260 of second family 209 is connected to third port
130 of first family 109. Gas from tank 1020 at this stage will
serve as the suction gas for compressor 500, and third tank 1030
will receive the discharge of compressor 500. Because check valves
1034, 1044, 1054, 1064, 1074, and 1084 respectively fluidly connect
in a one way (e.g., increasing) direction tanks 1040, 1050, 1060,
1070, and 1080 to each other (tank 1030 to 1040, 1040 to 1050, 1050
to 1060, 1060 to 1070, and 1070 to 1080) allowing higher pressure
gas to flow from lower numbered tanks to higher numbered tanks
assuming that the minimum check valve activation pressure can be
overcome) at this stage gas from tank 1020, although primarily
discharging to tank 1030 (through third port 130), Compressor 500
discharge gas also indirectly flows also to tanks 1040, 1050, 1060,
1070, and 1080. Because tank 1030 is at a higher pressure than tank
1020, check valve 1024 will prevent flow from tank 1030 to tank
1020.
Using both selector ports and check valve porting, Compressor 500
utilizes the 650 psig gas of tank 1020 to compress into tanks 1030,
1040, 1050, 1060, 1070, and 1080. Compressor 500 continues to run
until the pressure in tank 1020 drops to a predefined second tank
set point lower pressure (SP2.1) which in this embodiment can be
350 psig. However, it should be noted that SP2.1 is predetermined
such that it can be the most efficient pressure point, given the
challenge system 10's compressor 500 to compress with higher of a
differential pressures. During this stage it is noted that
compressor 500 is hermetically sealed, and the rear of piston 560
of compressor 500 sees the inlet pressure (i.e., the pressure of
being fed by tank 1020) and the discharge 520 sees the pressure in
tanks 1030, 1040, 1050, 1060, 1070, and 1080. Accordingly, in this
third stage when the pressure in tank 1020 drops to 350 psig the
differential that compressor 500 is attempting to compress over is
equal to the back pressure of the higher numbered tanks less than
the pressure in the current suction tank 1020.
The compressor 500 continues to run until the pressure in tank 1020
drops to SP2.1 at 350 psig. At this lower set point pressure,
system 10 proceeds back a step (or rolls back) to gain additional
moles of gas to refill tank 1020 up to its predefined SP2. Such
rolling back is called a wave, and system 10 has a choice of
whether to make the immediately proceeding staged tank in tank
array as the suction source for compressor 500 or go back to the
initial suction source of home gas 16. In this embodiment, system
10 going back multiple steps to home source 16 is disclosed.
Stage 1 WAVE
14. First staged tank 1010 is some amount between its predefined
SP1 of 150 psig and predefined lower SP1.1 of 100 psig, and will be
brought back up to its SP1 of 150 psig. Valve 100 is rotated to
Position 1 with home source 16 as suction and first staged tank
1010 as discharge for compressor 500. Gas at ambient temp from the
external supply at 0.5 psig flows through port 101 to the
Compressor 500 hermetic housing 504. Compressor 500 which is still
running utilizes the 0.5 psig gas to compress into tank 1010 until
tank 1010 reaches its predefined SP1 of 150 psig so that tank 1010
can be used as suction for the next staged compression step.
Stage 2 WAVE
15. Valve 100 is rotated to Position 2 with first staged tank 110
as the suction and second staged tank 1020 as the discharge. Gas at
ambient temp from tank 1010 at 150 psig flows through compressor
500 hermetic housing 504 and is compressed into tank 1020 which
starts initially at the lower second stage predefined set point
SP2.2. of 350 psig. Because at this point higher staged tanks are
at least at 650 psig, check valves 1034, 1044 do not allow gas to
flow through the check valve porting to the higher staged tanks and
gas only flows from discharge into second staged tank 1020.
Compressor 500 continues to run until the pressure in tank 1010
drops to SP1.1 at 100 psig. Note that the accomplishment of Step 14
and 15 takes approximately 27 minutes and accomplishes a 65 psig
differential pressure increase into second staged tank 1020.
16. Steps 14 and 15 are repeated 5 times, over a cumulative 2.2
hours
17. All steps above in Stage 3 are repeated 9 times over a 20 hour
period and this brings the pressures of staged pressure tanks 1030,
1040, 1050, 1060, 1070, 1080 up to 1150 psig which in this
embodiment is the predefined third staged pressure set point (SP3).
Each of the nine Stage 3 process sub-steps provides an
approximately 55 psig pressure gain in the higher staged tanks.
Stage 4 WAVE Position 4
18. The valve 100 is rotated to Position 4. In this stage the third
tank 1030 in staged tank array 1000 will be used as the suction
source for compressor 500 in filling higher stages of staged tank
array 1000 to a fourth predefined staged pressure set point (SP4)
which in this embodiment is 1,650 psig. Controller 2000 causes
valve 100 to be rotated to Position 4 wherein third selector port
130 of first family 109 is connected to second selector port 270 of
second family 209, and selector port 260 of second family 209 is
connected to fourth port 140 of first family 109. Gas from tank
1030 at this stage will serve as the suction gas for compressor
500, and fourth tank 1040 will receive the discharge of compressor
500. Because check valves 1054, 1064, 1074, and 1084 respectively
fluidly connect in a one way (e.g., increasing) direction tanks
1060, 1070, and 1080 to each other (tank 1050 to 1060, 1060 to
1070, and 1070 to 1080) allowing higher pressure gas to flow from
lower numbered tanks to higher numbered tanks assuming that the
minimum check valve activation pressure can be overcome) at this
stage gas from tank 1030, although primarily discharging to tank
1040 (through fourth port 140), compressor 500 discharge gas also
indirectly flows also to tanks 1060, 1070, and 1080. Because tank
1040 is at a higher pressure than tank 1030, check valve 1044 will
prevent flow from tank 1040 to tank 1030.
Using both selector ports and check valve porting, Compressor 500
utilizes the 1150 psig gas of tank 1030 to compress into tanks
1040, 1050, 1060, 1070, and 1080. Compressor 500 continues to run
until the pressure in tank 1030 drops to a predefined third tank
set point lower pressure (SP3.1) which in this embodiment can be
850 psig. However, it should be noted that SP3.1 is predetermined
such that it can be the most efficient pressure point, given the
challenge system 10's compressor 500 to compress with higher of a
differential pressures. During this stage it is noted that
compressor 500 is hermetically sealed, and the rear of piston 560
of compressor 500 sees the inlet pressure (i.e., the pressure of
being fed by tank 1030) and the discharge 520 sees the pressure in
tanks 1040, 1050, 1060, 1070, and 1080. Accordingly, in this fourth
stage when the pressure in tank 1030 drops to SP3.1 the
differential that compressor 500 is attempting to compress over is
equal to the back pressure of the higher numbered tanks less than
the pressure in the current suction tank 1030.
The compressor 500 continues to run until the pressure in tank 1030
drops to SP3.1 at 850 psig. At this lower set point pressure,
system 10 proceeds back a step (or rolls back or waves) to gain
additional moles of gas to refill tank 1030 up to its predefined
SP3. The system wave has a choice of whether to make the
immediately proceeding staged tank in tank array as the suction
source for compressor 500 or go back to the initial suction source
of home gas 16. In this embodiment, system 10 going back to
multiple steps to home source 16 is disclosed. System 10 now
proceeds back a step to gain additional moles of gas to refill tank
1030 up to SP3, and initiates waves which repeat steps comprising
portions of the steps disclosed in fill Stages 1, 2 and 3
Stage 1 WAVE
19. Valve 100 is rotated to Position 1 (external source 16
suction/first tank 1010 discharge) so that gas at ambient temp from
the external supply 16 at 0.5 psig flows through zero selector port
101 to compressor 500 hermetic housing 504, and is compressed into
first staged tank 1010. Compressor 500 continues to run until the
pressure in tank 1010 achieves SP1 at 150 psig at which point
system 10 enters wave 2.
Stage 2 WAVE
20. Valve 100 is rotated to Position 2 (first tank 1010
suction/second tank 1020 discharge) so that gas at ambient temp
from tank first staged 1010 of 150 psig flows through port 110 to
compressor 500 hermetic housing 504, and into second staged tank
1020. Compressor 500 continues to run until the pressure in first
staged tank 1010 drops to SP1.1 of 100 psig.
21. Steps 19 and 20 are repeated 5 times, over a cumulative 2.3
hours
Stage 3 WAVE
22. Valve 100 is rotated to Position 3 (second tank 1020
suction/third tank 1030 discharge) so that gas at ambient temp from
tank 1020 at SP2 of 650 psig flows to compressor 500 hermetic
housing 504, is compressed and discharged into third staged tank
1030. Compressor 500 continues to run until the pressure in second
staged tank 1020 drops to SP2.1 of 350 psig.
23. All steps above in Stage 4 are repeated 8 times over an 18 hour
period and this brings the pressure of staged tanks 1040, 1050,
1060, 1070, 1080 up to 1650 psig, SP4. Each of the 8 process steps
is increases higher staged pressures by about 62 psig.
Stage 5 WAVE Position 5
24. Valve 100 is rotated to Position 5. In this stage the fourth
tank 1040 in staged tank array 1000 will be used as the suction
source for compressor 500 in filling higher stages of staged tank
array 1000 to a fifth predefined staged pressure set point (SP5)
which in this embodiment is 2,150 psig. Controller 2000 causes
valve 100 to be rotated to Position 5, wherein fourth selector port
140 of first family 109 is connected to second selector port 270 of
second family 209, and selector port 260 of second family 209 is
connected to fifth port 150 of first family 109. Gas from tank 1040
at this stage will serve as the suction gas for compressor 500, and
fifth tank 1050 will receive the discharge of compressor 500.
Because check valves 1064, 1074, and 1084 respectively fluidly
connect in a one way (e.g., increasing) direction tanks 1060, 1070,
and 1080 to each other (tank 1050 to 1060, 1060 to 1070, and 1070
to 1080) allowing higher pressure gas to flow from lower numbered
tanks to higher numbered tanks assuming that the minimum check
valve activation pressure can be overcome at this stage gas from
tank 1040, although primarily discharging to tank 1050 (through
fifth port 150), compressor 500 discharge gas also indirectly flows
also to tanks 1060, 1070, and 1080. Because tank 1050 is at a
higher pressure than tank 1040, check valve 1044 will prevent flow
from tank 1050 to tank 1040.
Using both selector ports and check valve porting, Compressor 500
utilizes the 1650 psig gas of tank 1040 to compress into tanks
1050, 1060, 1070, and 1080. Compressor 500 continues to run until
the pressure in tank 1040 drops to a fourth predefined tank set
point lower pressure (SP4.1) which in this embodiment can be 1,350
psig. However, it should be noted that SP4.1 is predetermined such
that it can be the most efficient pressure point, given the
challenge system 10's compressor 500 to compress with higher of a
differential pressures. During this stage it is noted that
compressor 500 is hermetically sealed, and the rear of piston 560
of compressor 500 sees the inlet pressure (i.e., the pressure of
being fed by tank 1030) and the discharge 520 sees the pressure in
tanks 1050, 1060, 1070, and 1080. Accordingly, in this fourth stage
when the pressure in tank 1040 drops to SP4.1 the differential that
compressor 500 is attempting to compress over is equal to the back
pressure of the higher numbered tanks less than the pressure in the
current suction tank 1040.
The compressor 500 continues to run until the pressure in tank 1040
drops to SP4.1 at 1,150 psig. At this lower set point pressure,
system 10 proceeds back a step (or rolls back or waves) to gain
additional moles of gas to refill tank 1040 up to its predefined
SP4. The system wave has a choice of whether to make the
immediately proceeding staged tank in tank array as the suction
source for compressor 500 or go back to the initial suction source
of external gas 16. In this embodiment, system 10 going back to
multiple steps to external source 16 is disclosed. System 10 now
proceeds back a step to gain additional moles of gas to refill tank
1040 up to SP4, and initiates waves which repeat of steps
comprising portions of the steps disclosed in fill Stages 1, 2, 3,
and 4.
Stage 1 WAVE
25. Valve 100 is rotated to Position 1 (external source 16
suction/first tank 1010 discharge) so that gas at ambient temp from
the external supply 16 at 0.5 psig flows through zero selector port
101 to compressor 500 hermetic housing 504, and is compressed into
first staged tank 1010. Compressor 500 continues to run until the
pressure in tank 1010 achieves SP1 at 150 psig at which point
system 10 enters wave 2.
Stage 2 WAVE
26. Valve 100 is rotated to Position 2 (first tank 1010
suction/second tank 1020 discharge) so that gas at ambient temp
from tank first staged 1010 of 150 psig flows through port 110 to
compressor 500 hermetic housing 504, and into second staged tank
1020. Compressor 500 continues to run until the pressure in first
staged tank 1010 drops to SP1.1 of 100 psig.
27. Steps 26 and 27 are repeated 5 times, over a cumulative 2.4
hours
Stage 3 WAVE
28. Valve 100 is rotated to Position 3 (second tank 1020
suction/third tank 1030 discharge) so that gas at ambient temp from
tank 1020 at SP2 of 650 psig flows to compressor 500 hermetic
housing 504, is compressed and discharged into third staged tank
1030. Compressor 500 continues to run until the pressure in second
staged tank 1020 drops to SP2.1 of 350 psig.
Stage 4 WAVE
29. Valve 100 is rotated to Position 4 (third tank 1030
suction/fourth tank 1040 discharge) so that gas at ambient temp
from tank 1030 at SP3 of 1,150 psig flows to compressor 500
hermetic housing 504, is compressed and discharged into fourth
staged tank 1040. Compressor 500 continues to run until the
pressure in third staged tank 1030 drops to SP3.1 of 850 psig. Now
system 10 proceeds back a step to gain additional moles of gas to
refill third staged tank 1030 up to SP3 of 1,150 psig.
30. All steps above in Stage 5 are repeated 6 times over a 14 hour
period and this brings the pressure of tanks SP5 of 2,150 psig for
tanks 1050, 1060, 1070, 1080. Each of the six stage 5 process steps
is approximately 83 psig.
Stage 6 WAVE Position 6
31. Valve 100 is rotated to Position 6. In this stage the fifth
tank 1050 in staged tank array 1000 will be used as the suction
source for compressor 500 in filling higher stages of staged tank
array 1000 to a sixth predefined staged pressure set point (SP6)
which in this embodiment is 2,650 psig. Controller 2000 causes
valve 100 to be rotated to Position 6, wherein fifth selector port
150 of first family 109 is connected to second selector port 270 of
second family 209, and selector port 260 of second family 209 is
connected to sixth port 160 of first family 109. Gas from tank 1050
at this stage will serve as the suction gas for compressor 500, and
sixth tank 1060 will receive the discharge of compressor 500.
Because check valves 1074, and 1084 respectively fluidly connect in
a one way (e.g., increasing) direction tanks 1070 and 1080 to each
other (tank 1060 to 1070 and 1070 to 1080) allowing higher pressure
gas to flow from lower numbered tanks to higher numbered tanks
assuming that the minimum check valve activation pressure can be
overcome) at this stage gas from tank 1050, although primarily
discharging to tank 1060 (through sixth port 160), compressor 500
discharge gas also indirectly flows also to tanks 1070 and 1080.
Because tank 1060 is at a higher pressure than tank 1050, check
valve 1064 will prevent flow from tank 1060 to tank 1050.
Using both selector ports and check valve porting, Compressor 500
utilizes the 2,150 psig gas of tank 1050 to compress into tanks
1060, 1070, and 1080. Compressor 500 continues to run until the
pressure in tank 1050 drops to a fifth predefined tank set point
lower pressure (SP5.1) which in this embodiment can be 1,850 psig.
However, it should be noted that SP5.1 is predetermined such that
it can be the most efficient pressure point, given the challenge
system 10's compressor 500 to compress with higher of a
differential pressures. During this stage it is noted that
compressor 500 is hermetically sealed, and the rear of piston 560
of compressor 500 sees the inlet pressure (i.e., the pressure of
being fed by tank 1050) and the discharge 520 sees the pressure in
tanks 1060, 1070, and 1080. Accordingly, in this sixth stage when
the pressure in tank 1050 drops to SP5.1 the differential that
compressor 500 is attempting to compress over is equal to the back
pressure of the higher numbered tanks less than the pressure in the
current suction tank 1050.
The compressor 500 continues to run until the pressure in tank 1050
drops to SP5.1 at 1,850 psig. At this lower set point pressure,
system 10 proceeds back a step (or rolls back or waves) to gain
additional moles of gas to refill tank 1050 up to its predefined
SP5. The system wave has a choice of whether to make the
immediately proceeding staged tank in tank array as the suction
source for compressor 500 or go back to the initial suction source
of external gas 16. In this embodiment, system 10 going back to
multiple steps to external source 16 is disclosed. System 10 now
proceeds back a step to gain additional moles of gas to refill tank
1050 up to SP5, and initiates waves which repeat steps comprising
portions of the steps disclosed in fill Stages 1, 2, 3, 4, and
5.
Stage 1 WAVE
32. Valve 100 is rotated to Position 1 (external source 16
suction/first tank 1010 discharge) so that gas at ambient temp from
the external supply 16 at 0.5 psig flows through zero selector port
101 to compressor 500 hermetic housing 504, and is compressed into
first staged tank 1010. Compressor 500 continues to run until the
pressure in tank 1010 achieves SP1 at 150 psig at which point
system 10 enters wave 2.
Stage 2 WAVE
33. Valve 100 is rotated to Position 2 (first tank 1010
suction/second tank 1020 discharge) so that gas at ambient temp
from tank first staged 1010 of 150 psig flows through port 110 to
compressor 500 hermetic housing 504, and into second staged tank
1020. Compressor 500 continues to run until the pressure in first
staged tank 1010 drops to SP1.1 of 100 psig.
34. Steps 32 and 33 are repeated 5 times, over a cumulative 2.5
hours
Stage 3 WAVE
35. Valve 100 is rotated to Position 3 (second tank 1020
suction/third tank 1030 discharge) so that gas at ambient temp from
tank 1020 at SP2 of 650 psig flows to compressor 500 hermetic
housing 504, is compressed and discharged into third staged tank
1030. Compressor 500 continues to run until the pressure in second
staged tank 1020 drops to SP2.1 of 350 psig.
Stage 4 WAVE
36. Valve 100 is rotated to Position 4 (third tank 1030
suction/fourth tank 1040 discharge) so that gas at ambient temp
from tank 1030 at SP3 of 1,150 psig flows to compressor 500
hermetic housing 504, is compressed and discharged into fourth
staged tank 1040. Compressor 500 continues to run until the
pressure in third staged tank 1030 drops to SP3.1 of 850 psig.
Stage 5 WAVE
37A. Valve 100 is rotated to Position 5 (fourth tank 1040
suction/fifth tank 1050 discharge) so that gas at ambient temp from
tank 1040 at SP3 of 1,650 psig flows to compressor 500 hermetic
housing 504, is compressed and discharged into fifth staged tank
1050. Compressor 500 continues to run until the pressure in fourth
staged tank 1040 drops to SP4.1 of 1,350 psig.
Stage 6 WAVE
37B. Valve 100 is rotated to Position 6 (fifth tank 1050
suction/sixth tank 1060 discharge) so that gas at ambient temp from
tank 1050 at SP5 of 2,150 psig flows to compressor 500 hermetic
housing 504, is compressed and discharged into sixth staged tank
1060. Compressor 500 continues to run until the pressure in fifth
staged tank 1050 drops to SP5.1 of 1,850 psig.
38. All steps above in Stage 6 are repeated 4 times over a 10 hour
period and this brings the pressure of stages tanks up to the sixth
predefined staged pressure point of 2,650 psig (tanks 1060, 1070,
and 1080). Each of the four stage 6 process steps is approximately
125 psig.
Stage 7 WAVE Position 7
39. Valve 100 is rotated to Position 7. In this stage the sixth
tank 1060 in staged tank array 1000 will be used as the suction
source for compressor 500 in filling higher stages of staged tank
array 1000 to a seventh predefined staged pressure set point (SP7)
which in this embodiment is 3,150 psig. Controller 2000 causes
valve 100 to be rotated to Position 7, wherein sixth selector port
160 of first family 109 is connected to second selector port 270 of
second family 209, and selector port 260 of second family 209 is
connected to seventh port 170 of first family 109. Gas from tank
1060 at this stage will serve as the suction gas for compressor
500, and seventh tank 1070 will receive the discharge of compressor
500. Because check valve 1084 fluidly connects in a one way (e.g.,
increasing) direction tanks 1070 and 1080 to each other (tank 1070
to 1080) allowing higher pressure gas to flow from lower numbered
tank 1070 to higher numbered tank 1080, assuming that the minimum
check valve activation pressure can be overcome, at this stage gas
from tank 1060, although primarily discharging to tank 1070
(through seventh port 170), compressor 500 discharge gas also
indirectly flows also to tank 1080. Because tank 1070 is at a
higher pressure than tank 1060, check valve 1074 will prevent flow
from tank 1070 to tank 1060.
Using both selector ports and check valve porting, Compressor 500
utilizes the 2,650 psig gas of tank 1060 to compress into tanks
1070 and 1080. Compressor 500 continues to run until the pressure
in tank 1060 drops to a sixth predefined tank set point lower
pressure (SP6.1) which in this embodiment can be 2,350 psig.
However, it should be noted that SP6.1 is predetermined such that
it can be the most efficient pressure point, given the challenge
system 10's compressor 500 to compress with higher of a
differential pressures. During this stage it is noted that
compressor 500 is hermetically sealed, and the rear of piston 560
of compressor 500 sees the inlet pressure (i.e., the pressure of
being fed by tank 1060) and the discharge 520 sees the pressure in
tanks 1070 and 1080. Accordingly, in this seventh stage when the
pressure in tank 1060 drops to SP6.1 the differential that
compressor 500 is attempting to compress over is equal to the back
pressure of the higher numbered tanks less than the pressure in the
current suction tank 1060.
The compressor 500 continues to run until the pressure in tank 1060
drops to SP6.1 at 2,350 psig. At this lower set point pressure,
system 10 proceeds back a step (or rolls back or waves) to gain
additional moles of gas to refill tank 1060 up to its predefined
SP6. The system wave has a choice of whether to make the
immediately proceeding staged tank in tank array as the suction
source for compressor 500 or go back to the initial suction source
of external gas 16. In this embodiment, system 10 going back to
multiple steps to external source 16 is disclosed. System 10 now
proceeds back a step to gain additional moles of gas to refill tank
1060 up to SP6, and initiates waves which repeat of steps
comprising portions of the steps disclosed in fill Stages 1, 2, 3,
4, 5, and 6.
Stage 1 WAVE
40. Valve 100 is rotated to Position 1 (external source 16
suction/first tank 1010 discharge) so that gas at ambient temp from
the external supply 16 at 0.5 psig flows through zero selector port
101 to compressor 500 hermetic housing 504, and is compressed into
first staged tank 1010. Compressor 500 continues to run until the
pressure in tank 1010 achieves SP1 at 150 psig at which point
system 10 enters wave 2.
Stage 2 WAVE
41. Valve 100 is rotated to Position 2 (first tank 1010
suction/second tank 1020 discharge) so that gas at ambient temp
from tank first staged 1010 of 150 psig flows through port 110 to
compressor 500 hermetic housing 504, and into second staged tank
1020. Compressor 500 continues to run until the pressure in first
staged tank 1010 drops to SP1.1 of 100 psig.
42. Steps 40 and 41 are repeated 5 times, over a cumulative 2.5
hours
Stage 3 WAVE
43. Valve 100 is rotated to Position 3 (second tank 1020
suction/third tank 1030 discharge) so that gas at ambient temp from
tank 1020 at SP2 of 650 psig flows to compressor 500 hermetic
housing 504, is compressed and discharged into third staged tank
1030. Compressor 500 continues to run until the pressure in second
staged tank 1020 drops to SP2.1 of 350 psig. Now system 10 proceeds
back a step to gain additional moles of gas to refill second staged
tank 1020 up to SP2 of 650 psig.
Stage 4 WAVE
44. Valve 100 is rotated to Position 4 (third tank 1030
suction/fourth tank 1040 discharge) so that gas at ambient temp
from tank 1030 at SP3 of 1,150 psig flows to compressor 500
hermetic housing 504, is compressed and discharged into fourth
staged tank 1040. Compressor 500 continues to run until the
pressure in third staged tank 1030 drops to SP3.1 of 850 psig.
Stage 5 WAVE
45. Valve 100 is rotated to Position 5 (fourth tank 1040
suction/fifth tank 1050 discharge) so that gas at ambient temp from
tank 1040 at SP3 of 1,650 psig flows to compressor 500 hermetic
housing 504, is compressed and discharged into fifth staged tank
1050. Compressor 500 continues to run until the pressure in fourth
staged tank 1040 drops to SP4.1 of 1,350 psig.
Stage 6 WAVE
46. Valve 100 is rotated to Position 6 (fifth tank 1050
suction/sixth tank 1060 discharge) so that gas at ambient temp from
tank 1050 at SP5 of 2,150 psig flows to compressor 500 hermetic
housing 504, is compressed and discharged into sixth staged tank
1060. Compressor 500 continues to run until the pressure in fifth
staged tank 1050 drops to SP5.1 of 1,850 psig.
47. All steps above in Stage 7 are repeated 3 times over a 7 hour
period and this brings the pressure of staged tanks 1070 1080 up to
the seventh predefined staged pressure point SP7 of 3,650 psig
(tanks 1070 and 1080). Each of the three stage 7 process steps is
approximately 165 psig.
Stage 8 WAVE Position 8
48. Valve 100 is rotated to Position 8. In this stage the seventh
tank 1070 in staged tank array 1000 will be used as the suction
source for compressor 500 in filling higher stages of staged tank
array 1000 to an eighth predefined staged pressure set point (SP8)
which in this embodiment is 3,650 psig. Controller 2000 causes
valve 100 to be rotated to Position 8, wherein seventh selector
port 170 of first family 109 is connected to second selector port
270 of second family 209, and selector port 260 of second family
209 is connected to eighth port 170 of first family 109. Gas from
tank 1070 at this stage will serve as the suction gas for
compressor 500, and eighth tank 1080 will receive the discharge of
compressor 500. Because tank 1080 is at a higher pressure than tank
1070, check valve 1084 will prevent flow from tank 1080 to tank
1070.
Using both selector ports and check valve porting, Compressor 500
utilizes the 2,650 psig gas of tank 1070 to compress into tank
1080. Compressor 500 continues to run until the pressure in tank
1070 drops to a seventh predefined tank set point lower pressure
(SP7.1) which in this embodiment can be 2,850 psig. However, it
should be noted that SP7.1 is predetermined such that it can be the
most efficient pressure point, given the challenge system 10's
compressor 500 to compress with higher of a differential pressures.
During this stage it is noted that compressor 500 is hermetically
sealed, and the rear of piston 560 of compressor 500 sees the inlet
pressure (i.e., the pressure of being fed by tank 1070) and the
discharge 520 sees the pressure in tank 1080. Accordingly, in this
eighth stage when the pressure in tank 1070 drops to SP7.1 the
differential that compressor 500 is attempting to compress over is
equal to the back pressure of tank 1080 less the pressure in the
current suction tank 1070.
The compressor 500 continues to run until the pressure in tank 1070
drops to SP7.1 at 2,850 psig. At this lower set point pressure,
system 10 proceeds back a step (or rolls back or waves) to gain
additional moles of gas to refill tank 1070 up to its predefined
SP7. The system wave has a choice of whether to make the
immediately proceeding staged tank in tank array as the suction
source for compressor 500 or go back to the initial suction source
of external gas 16. In this embodiment, system 10 going back to
multiple steps to external source 16 is disclosed. System 10 now
proceeds back a step to gain additional moles of gas to refill tank
1070 up to SP7, and initiates waves which repeat of steps
comprising portions of the steps disclosed in fill Stages 1, 2, 3,
4, 5, 6, and 7.
Stage 1 WAVE
49. Valve 100 is rotated to Position 1 (external source 16
suction/first tank 1010 discharge) so that gas at ambient temp from
the external supply 16 at 0.5 psig flows through zero selector port
101 to compressor 500 hermetic housing 504, and is compressed into
first staged tank 1010. Compressor 500 continues to run until the
pressure in tank 1010 achieves SP1 at 150 psig at which point
system 10 enters wave 2.
Stage 2 WAVE
50. Valve 100 is rotated to Position 2 (first tank 1010
suction/second tank 1020 discharge) so that gas at ambient temp
from tank first staged 1010 of 150 psig flows through port 110 to
compressor 500 hermetic housing 504, and into second staged tank
1020. Compressor 500 continues to run until the pressure in first
staged tank 1010 drops to SP1.1 of 100 psig.
51. Steps 49 and 50 are repeated 5 times, over a cumulative 2.5
hours Stage 3 WAVE
52. Valve 100 is rotated to Position 3 (second tank 1020
suction/third tank 1030 discharge) so that gas at ambient temp from
tank 1020 at SP2 of 650 psig flows to compressor 500 hermetic
housing 504, is compressed and discharged into third staged tank
1030. Compressor 500 continues to run until the pressure in second
staged tank 1020 drops to SP2.1 of 350 psig.
Stage 4 WAVE
53. Valve 100 is rotated to Position 4 (third tank 1030
suction/fourth tank 1040 discharge) so that gas at ambient temp
from tank 1030 at SP3 of 1,150 psig flows to compressor 500
hermetic housing 504, is compressed and discharged into fourth
staged tank 1040. Compressor 500 continues to run until the
pressure in third staged tank 1030 drops to SP3.1 of 850 psig.
Stage 5 WAVE
54. Valve 100 is rotated to Position 5 (fourth tank 1040
suction/fifth tank 1050 discharge) so that gas at ambient temp from
tank 1040 at SP4 of 1,650 psig flows to compressor 500 hermetic
housing 504, is compressed and discharged into fifth staged tank
1050. Compressor 500 continues to run until the pressure in fourth
staged tank 1040 drops to SP4.1 of 1,350 psig.
Stage 6 WAVE
55. Valve 100 is rotated to Position 6 (fifth tank 1050
suction/sixth tank 1060 discharge) so that gas at ambient temp from
tank 1050 at SP5 of 2,150 psig flows to compressor 500 hermetic
housing 504, is compressed and discharged into sixth staged tank
1060. Compressor 500 continues to run until the pressure in fifth
staged tank 1050 drops to SP5.1 of 1,850 psig.
Stage 7 WAVE
56. Valve 100 is rotated to Position 7 (sixth tank 1060
suction/seventh tank 1070 discharge) so that gas at ambient temp
from tank 1060 at SP6 of 2,650 psig flows to compressor 500
hermetic housing 504, is compressed and discharged into seventh
staged tank 1070. Compressor 500 continues to run until the
pressure in sixth staged tank 1060 drops to SP6.1 of 2,350
psig.
Stage 8 WAVE
57. Valve 100 is rotated to Position 8 (seventh tank 1070
suction/eighth tank discharge) so that gas at ambient temp from
tank 1070 at SP7 of 3,150 psig flows to compressor 500 hermetic
housing 504, is compressed and discharged into eighth staged tank
1080. Compressor 500 continues to run until the pressure in seventh
staged tank 1070 drops to SP7.1 of 2,850 psig.
58. All steps above in Stage 8 are only accomplished once over a 2
hour period, for a process subtotal runtime of approximately 103
hours, and this brings the pressure of tank 1080 up to 3650 psig,
SP8. The single 8 WAVE step is approximately 500 psig.
59. Valve 100 is rotated to accomplish Stage 1, 2, 3, 4, 5, 6 and
then Stage 7 WAVE processes in order to bring Stage 7 up from SP7.1
to SP7.
60. Valve 100 is rotated to accomplish Stage 1, 2, 3, 4, 5 and then
Stage 6 WAVE processes in order to bring Stage 6 up from SP6.1 to
SP6.
61. Valve 100 is rotated to accomplish Stage 1, 2, 3, 4 and then
Stage 5 WAVE processes in order to bring Stage 5 up from SP5.1 to
SP5.
62. Valve 100 is rotated to accomplish Stage 1, 2, 3 and then Stage
4 WAVE processes in order to bring Stage 4 up from SP4.1 to
SP4.
63. Valve 100 is rotated to accomplish Stage 1, 2 and then Stage 3
WAVE processes in order to bring Stage 3 up from SP3.1 to SP3.
64. Valve 100 is rotated to accomplish Stage 1 and then Stage 2
WAVE processes in order to bring Stage 2 up from SP2.1 to SP2.
65. Valve 100 is rotated to accomplish Stage 1 replenishment
process in order to bring Stage 1 up from SP1.1 to SP1.
66. After a cumulative run-time of approximately 113 hours the
entire system 10 is full and either ready for Off-loading or for
additional work on the alternate embodiment of system 10,
Compressor 500 is stopped, and valve 100 is rotated to the Null
Position or Position 1.
In one embodiment, Position 9 can be defined as both ports 260 and
270 as resting over blank seals. For practical reasons, it is
usually sufficient to park the suction over a blank port or the
discharge over a blank port (Position 9 as shown in FIG. 1A).
Position 9 can be used when compressor 500 is actively filling
vehicle car. Position 0 (not shown in FIG. 1A)=port 270 blanked
off, Port 260 to port 101 is where system 10 can normally rest
after staged tank array 1000 is full. Position 9=Port 270 to port
180 and port 260 blanked off is where system 10 preferably sits
during an active compressor suction to vehicle 20. Position NULL
would be defined as both ports 260 and 270 blanked off but in
practice is not normally required. Instead, system 10 can normally
use Position 0 instead (which can include the possibility of using
an extra position is somehow an end run. Additionally, it is
preferred that valve 100 not be operated where it is moved from
Position 9 to Position 1.
Overall System Off-Loading Process
This section will include a brief overview of using one embodiment
of system 10 in an Off-loading Process (filling a car tank or other
device/medium), by utilizing differential pressure transfers
between two devices coupled with the Work Adjusted Volumetric
Efficient (WAVE) methodology for moving compressed gas through the
Compressor 500 but this time into a car tank or other device.
The Off-load Process benefits from the higher stored pressures
during the simple transfer phase and is therefore more efficiently
able to then WAVE process move gas to the destination tank(s)
during the System 10 compression phase II and III portion of the
process. This in turn allows the System 10 Refresh Process to
therefore more quickly and efficiently replenish the System 10
System by utilizing the System 10 Refresh Process.
FIGS. 47-54 depict typical System 10 System off-loading of gas to
destination tank(s) and are described below as the System 10
Off-load Processes Phase I, II and III.
Example 1: Offloading to 100% Empty Destination
Phase I
Off-Load Stage 1 Transfer
1. Valve 100 is rotated to Position 1. Valve 524 is closed, and
valves 528 and 532 are opened. Gas at ambient temp from tank 1010
at SP1, 150 psig, flows through first selector port 110 of first
family 109 to first selector port 260 of second family 209, through
tee 53, and to the vehicle tank(s)/destination. The gas will either
stop or continue to flow into the destination tank(s), series of
tanks or other flow path.
If the flow of the gas stops then this either signifies the car's
tank(s) is at a pressure greater than the supplying tank's gas
pressure. If the flow continues, the destination tank(s) will then
come into a pressure equalization setting shared with the System 10
System source tank. Once equalization has been achieved, system 10
will proceed to the next Stage.
Off-Load Stage 2 Transfer
2. Valve 100 is rotated to Position 2. Gas at ambient temp from
tank 1020 at SP2, 650 psig, flows through first second selector
port 120 of first family 109 to first selector port 260 of second
family 209, through tee 53, and to the vehicle tank(s)/destination.
The gas will either stop or continue to flow into the destination
tank(s), series of tanks or other flow path.
If the flow of the gas stops then this either signifies the car's
tank(s) is at a pressure greater than the supplying tank's gas
pressure. If the flow continues, the destination tank(s) will then
come into a pressure equalization setting shared with the System 10
source tank. Once equalization has been achieved, system 10 will
proceed to the next Stage
Off-Load Stage 3 Transfer
3. Valve 100 is rotated to Position 3. Gas at ambient temp from
tank 1030 at SP3, 1,150 psig, flows through third selector port 130
of first family 109 to first selector port 260 of second family
209, through tee 53, and to the vehicle tank(s)/destination. The
gas will either stop or continue to flow into the destination
tank(s), series of tanks or other flow path.
If the flow of the gas stops then this either signifies the car's
tank(s) is at a pressure greater than the supplying tank's gas
pressure. If the flow continues, the destination tank(s) will then
come into a pressure equalization setting shared with the System 10
System source tank. Once equalization has been achieved, system 10
will proceed to the next Stage
Off-Load Stage 4 Transfer
4. Valve 100 is rotated to Position 4. Gas at ambient temp from
tank 1040 at SP4, 1650 psig, flows through fourth selector port 140
of first family 109 to first selector port 260 of second family
209, through tee 53, and to the vehicle tank(s)/destination. The
gas will either stop or continue to flow into the destination
tank(s), series of tanks or other flow path.
If the flow of the gas stops then this either signifies the car's
tank(s) is at a pressure greater than the supplying tank's gas
pressure. If the flow continues, the destination tank(s) will then
come into a pressure equalization setting shared with the System 10
System source tank. Once equalization has been achieved, system 10
will proceed to the next Stage.
Off-Load Stage 5 Transfer
5. Valve 100 is rotated to Position 5. Gas at ambient temp from
tank 1050 at SP5, 2150 psig, flows through fifth selector port 150
of first family 109 to first selector port 260 of second family
209, through tee 53, and to the vehicle tank(s)/destination. The
gas will either stop or continue to flow into the destination
tank(s), series of tanks or other flow path.
If the flow of the gas stops then this either signifies the car's
tank(s) is at a pressure greater than the supplying tank's gas
pressure. If the flow continues, the destination tank(s) will then
come into a pressure equalization setting shared with the source
tank. Once equalization has been achieved, system 10 will proceed
to the next Stage.
Off-Load Stage 6 Transfer
6. Valve 100 is rotated to Position 6. gas at ambient temp from
tank 1060 at SP6, 2650 psig, flows through sixth selector port 160
of first family 109 to first selector port 260 of second family
209, through tee 53, and to the vehicle tank(s)/destination. The
gas will either stop or continue to flow into the destination
tank(s), series of tanks or other flow path.
If the flow of the gas stops then this either signifies the car's
tank(s) is at a pressure greater than the supplying tank's gas
pressure. If the flow continues, the destination tank(s) will then
come into a pressure equalization setting shared with the source
tank. Once equalization has been achieved, system 10 will proceed
to the Stage.
Off-Load Stage 7 Transfer
7. Valve 100 is rotated to Position 7. Gas at ambient temp from
tank 1070 at SP7, 3150 psig, flows through first seventh port 170
of first family 109 to first selector port 260 of second family
209, through tee 53, and to the vehicle tank(s)/destination. The
gas will either stop or continue to flow into the destination
tank(s), series of tanks or other flow path.
If the flow of the gas stops then this either signifies the car's
tank(s) is at a pressure greater than the supplying tank's gas
pressure. If the flow continues, the destination tank(s) will then
come into a pressure equalization setting shared with the source
tank. Once equalization has been achieved, system 10 will proceed
to the Stage
Off-Load Stage 8 Transfer
8. Valve 100 is rotated to Position 8. Gas at ambient temp from
tank 1080 at SP8, 3650 psig, flows through eighth selector port 180
of first family 109 to first selector port 260 of second family
209, through tee 53, and to the vehicle tank(s)/destination. The
gas will either stop or continue to flow into the destination
tank(s).
If the flow of the gas stops then the process is complete. If the
flow continues, the destination tank(s) will then come into a
pressure equalization setting shared with the source tank. Once
equalization has been achieved, the Fill Phase I is complete. It
should be noted that system 10 has now completed Phase 1 of the
Off-Load Process and is ready to perform the WAVE Off-load Phase
II. In one embodiment a user can have the choice to continue or not
continue with process of WAVE offloads or offloading.
Phase II
1. Valve 532 is closed.
2. Valve 524 and 528 are open.
3. The Compressor 500 is started.
Off-Load Stage 2 WAVE
4. Valve 100 is rotated to Position 2. Gas at ambient temp from
tank 1010 at SP1.3 psig flows through port 110 of first family of
ports 109 to second port 270 of second family of ports 209, to
input 510, and to compressor 500 hermetic housing 504.
Compressor 500 which is still running further compresses the
pressurized psig gas of tank 1010 to compress and discharges such
gas into tank 1020. The compressor continues to run until the
pressure in tank 1020 rises to be approximately 500 psig higher
than the falling pressure of tank 1010
Off-Load Stage 3 WAVE
5. The Valve 100 is rotated to Position 3. Gas at below ambient
temp from tank 1020, SP2.3, flows through port 120 of first family
of ports 109 to second port 270 of second family of ports 209, to
input 510, and to compressor 500 hermetic housing 504. Compressor
500 which is still running further compresses the
pressurized/compressed gas of tank 1020 and discharges such gas
into tank 1030. Compressor 500 continues to run until the pressure
in tank 1030 rises to be approximately 500 psig higher than the
falling pressure of tank 1020
Off-Load Stage 4 WAVE
6. Valve 100 is rotated to Position 4. Gas at ambient temp from
tank 1030, SP3.3, flows through port 130 of first family of ports
109 to second port 270 of second family of ports 209, to input 510,
and to compressor 500 hermetic housing 504. Compressor 500 which is
still running further compresses the pressurized/compressed gas of
tank 1030 and discharges such gas into tank 1040. Compressor 500
continues to run until the pressure in tank 1040 rises to be
approximately 500 psig higher than the falling pressure of tank
1030.
Off-Load Stage 5 WAVE
7. Valve 100 is rotated to Position 5. Gas at ambient temp from
tank 1040, SP4.3, flows through port 150 of first family of ports
109 to second port 270 of second family of ports 209, to input 510,
and to compressor 500 hermetic housing 504. Compressor 500 which is
still running further compresses the pressurize/compressed gas of
tank 1040 and discharges such gas into tank 1050. Compressor 500
continues to run until the pressure in tank 1050 rises to be
approximately 500 psig higher than the falling pressure of tank
1040.
Off-Load Stage 6 WAVE
8. Valve 100 is rotated to Position 6. Gas at ambient temp from
tank 1050, SP5.3, flows through port 150 of first family of ports
109 to second port 270 of second family of ports 209, to input 510,
and to compressor 500 hermetic housing 504. Compressor 500 which is
still running further compresses the pressurized/compressed gas of
tank 1050 and discharges such gas into tank 1060. Compressor 500
continues to run until the pressure in tank 1060 rises to be
approximately 500 psig higher than the falling pressure of tank
1050.
Off-Load Stage 7 WAVE
9. Valve 100 is rotated to Position 7. Gas at ambient temp from
tank 1060, SP6.3, flows through port 160 of first family of ports
109 to second port 270 of second family of ports 209, to input 510,
and to compressor 500 hermetic housing 504. Compressor 500 which is
still running further compresses the pressurized/compressed gas of
tank 1060 and discharges such gas into tank 1070. Compressor 500
continues to run until the pressure in tank 1070 rises to be
approximately 500 psig higher than the falling pressure of tank
1060.
Off-Load Stage 8 WAVE
10. Valve 100 is rotated to Position 8. Gas at ambient temp from
tank 1070, SP7.3, flows through port 170 of first family of ports
109 to second port 270 of second family of ports 209, to input 510,
and to compressor 500 hermetic housing 504. Compressor 500 which is
still running further compresses the pressurized/compressed gas of
tank 1070 and discharges such gas into tank 1080. Compressor 500
continues to run until the pressure in tank 1080 rises to be
approximately 500 psig higher than the falling pressure of tank
1070.
Phase III
NOTE: The accomplishment of the above described Off-load Process
Phase II now has system 10 ready for utilization of compressor 500
to move gas from tank 1080 to the vehicle tank(s)/destination, with
an additional 500 delta pressure WAVE.
11. Valve 528 is closed, and valves 524 and 532 are opened.
12. Valve 100 is rotated to Position 9 (shown FIG. 1A rotated
clockwise relative to Position 8 in FIG. 1A). Gas at ambient temp
from tank 1080 flows through eighth port 180 of first family 109 to
second selector port 270 of second family 209, and to compressor
500 hermetic housing 504. Compressor 500 which is still running
further compresses the pressurized/compressed gas of tank 1080 and
discharges such gas into the vehicle tank(s)/destination.
Compressor 5000 continues to run until the pressure of tank 1080
decreases to SP8.2 which is the current pressure of tank 1080
(SP8.3) minus 200 psi. Correspondingly, System 10 is able to stop
the process flow as based on known to the industry practices of
motor amperage draw, compressor delta P measurements.
13. The above series of Off-load Process WAVE Stages can be
performed if, and as many times as needed, to the point where the
allowable Compressor 500 P/D has been exceeded. The methodology for
predetermining the number of times to repeat the process is
described above. System 10 can be purposely sized such that the
ability to over pressurize the destination tank is not possible
because compressor 500 can be uniquely sized, in conjunction with
the tank set points to not have the ability to compress over a
specific delta P.
14. This entire described Off-load Process, with only a single WAVE
took approximately 13 minutes for a 100% depleted destination
tank.
15. The above Off-load Process, Phases II and III can be repeated
as needed to accomplish the System 10's needs.
16. Valve 532 is closed, and valves 524 and 528 are opened.
Example 2: Offloading to 95% Full Destination
Phase I
1. The Off-load Process needs to deliver a quantity of gas to the
vehicle (exampled here as a destination tank of 100 L, arriving at
approximately 3420 psig for a fill).
2. Valve 524 is closed, and valves 528 and 532 are opened. System
10 by the means previously discussed embodiment regarding an
ability to receive user interface, for this example, system 10
knows approximately what the pressure of the destination tank is.
Therefore, system 10 has chosen not to perform a WAVE from Tank
1010, 1020, 1030, 1040, 1050, 1060, 1070 and 1080, and not to
perform a reverse WAVE from Tank 1080, 1070, 1060, 1050, 1040,
1030, 1020, and 1010. Instead, system 10 has chosen, in this
example to start the Off-load Process at valve Position 6, tank
1060.
3. System 10 rotates valve 100 to Position 6 (attempting to offload
from tank 1060) and no gas flows from system 10 because the
vehicle/destination is at 3420 psig. which is greater than the
pressure in tank 1060.
4. System 10 rotates valve 100 to Position 7 and no gas flowed from
system 10 because the vehicle/destination is at 3420 psig. which is
greater than the pressure in tank 1070.
Off-Load Stage 8 Transfer
5. Valve 100 is rotated to Position 8. Gas at ambient temp from
tank 1080 at SP8, 3650 psig, flows through eighth selector port 110
of first family 109 to first selector port 260 of second family
209, through tee 53, and towards to car tank(s)/destination. Once
the flow rate virtually stops, the destination tank(s) will then be
at a pressure equalization setting shared with the system 10 source
tank. This is approximately 3,490 psi (dependent on tank
temperatures and other known to the industry factors)
Phase II
System 10 by the means previously discussed with regards to its
ability to calculate the approximate need of the destination tank,
has determined that it only needs to perform an Off-load WAVE
utilizing only the gas in tank 1080. An Off-load Process WAVE from
any lower tank was not needed.
Phase III
6. Valve 532 is opened.
7. Valve 524 is opened and valve 528 is closed.
8. Compressor 500 is started.
9. Valve 100 is rotated to Position 9. Gas at ambient temp from
tank 1080, which is in equilibrium pressure with the destination
tank at approximately 3,420 psi, SP8.3 flows through eighth
selector port 110 of first family 109 to first selector port 260 of
second family 209, and to compressor 500 hermetic housing 504.
Compressor 500 which is still running further compresses the SP8.3
gas of tank 1080, and discharges such compressed gas into the
destination tank. Compressor 500 continues to run until the
pressure of tank 1080 decreases to SP8.2 which equals the initial
pressure of tank 1080 (SP8.3) minus 350 psi. However, the setting
of SP8.2 to 350 psi less than SP8.3 could be varied due to system
10 status and sizing and temperatures. Correspondingly, system 10
is also able to stop the process flow as based on known to the
industry practices of motor amperage draw, compressor delta P
measurements, etc.
10. The destination tank is approximately at 3,600 psi and this
entire Off-load process took approximately 0.5 minutes to
accomplish for a destination tank that was 95% full.
11. Valve 532 is closed, and valves 524 and 528 are opened.
Example 3: Offloading to Two-Thirds Full Destination
Phase I
1. The Off-load Process needs to deliver a quantity of gas to the
vehicle (used and an example here as a destination tank of 100 L,
arriving at approximately 2,400 psi. for a fill).
2. Valve 524 is closed, and valves 528 and 532 are opened.
Off-Load Stage 5 Transfer
3. Controller 2000 rotates valve 100 to Position 5 and no gas flows
from the system 10 because the vehicle/destination tank 1050 is
higher than SP5 at 2,150 psi. System 10 is now ready to proceed to
the next Stage.
Off-Load Stage 6 Transfer
4. The Valve 100 is rotated to Position 6. Gas at ambient temp from
tank 1060 at SP6 2,650 psig flows through sixth selector port 160
of first family 109 to first selector port 260 of second family
209, through tee 53, and towards the either car tank(s) or other
destination. The flow continues and the destination tank(s) come
into a pressure equalization setting shared with the System 10
source tank at approximately 2,400 psi. System 10 is now ready to
proceed to the next System 10 Stage
Off-Load Stage 7 Transfer
5. The Valve 100 is rotated to Position 7. Gas at ambient temp from
tank 1070 at SP7, 3150 psig, flows through seventh selector port
170 of first family 109 to first selector port 260 of second family
209, through tee 53, and towards the either car tank(s) or other
destination. The flow continues, the destination tank(s) come into
a pressure equalization setting shared with the System 10 System
source tank at approximately 2,675 psi. System 10 is now ready to
proceed to the next Stage.
Off-Load Stage 8 Transfer
6. The Valve 100 is rotated to Position 8. Gas at ambient temp from
tank 1080 at SP8, 3650 psig, flows through eighth selector port 180
of first family 109 to first selector port 260 of second family
209, through tee 53, and towards the either car tank(s) or other
destination. The flow rate continues, the destination tank(s) come
into a pressure equalization setting shared with the System 10
System source tank at approximately 2,950 psi. NOTE: System 10 has
now completed Phase 1 of the Off-Load Process and is ready to
perform the WAVE Off-load Phase II
Phase II
7. Valve 532 is closed.
8. Valve 524 is opened.
9. Compressor 500 is started. NOTE: In this example of Off-load
Process WAVE methodology, system 10 has determined that the
allowable delta P between Stages 5 and 6 is such that the system
can quickly and easily attain a destination set point at
approximately 3,250 psi and alerts the user to choosing a quick
fill or 3,200 psi in 1.0 minutes, or for a complete fill to 3,600
psi within 15 minutes. For the purposes of this example the use has
chosen to perform a complete fill to 3,600 psi.
Off-Load Stage 6 WAVE
10. The Valve 100 is rotated to Position 6. Gas at ambient temp
from tank 1050, SP5 at 2,150 psi, flows to compressor 500 hermetic
housing 504. Compressor 500 which is still running utilizes the gas
of tank 1050 to compress into tank 1060. Compressor 500 continues
to run until the pressure in tank 1060 rises to be approximately
500 psig higher than the falling pressure of tank 1050 which is now
at 2,000 psi.
Off-Load Stage 7 WAVE
11. The Valve 100 is rotated to Position 7. Gas at ambient temp
from tank 1060, SP6.3 at 2,480 psi flows to the Compressor 500
hermetic housing 504. Compressor 500 which is still running
utilizes the gas of tank 1060 to compress into tank 1070.
Compressor 500 continues to run until the pressure in tank 1070
rises to be approximately 500 psig higher than the falling pressure
of tank 1060 which is now at 2,375 psi.
Off-Load Stage 8 WAVE
12. Valve 100 is rotated to Position 8. Gas at ambient temp from
tank 1070, SP7.3 at 2,810 psi, flows to compressor 500 hermetic
housing 504. Compressor 500 which is still running utilizes the gas
of tank 1070 to compress into tank 1080. Compressor 500 continues
to run until the pressure in tank 1080 rises to be approximately
500 psig higher than the falling pressure of tank 1070 which is now
at 2,620 psi.
Phase III
NOTE: The accomplishment of the Off-load Process second phase now
has system 10 ready for utilization of compressor 500 to move gas
from tank 1080 to the vehicle tank(s)/destination.
13. Valve 532 is opened, valve 524 is opened, valve 528 is closed,
and compressor 500 is started.
14. The Valve 100 is rotated to Position 9. Gas at ambient temp
from tank 1080 flows to the Compressor 500 hermetic housing 504.
Compressor 500 which is still running compresses the pressurized
gas of tank 1080 and discharges such gas into the vehicle
tank(s)/destination. Compressor 500 continues to run until the
pressure of tank 1080 decreases to SP8.2 which is approximately 200
psi less than the starting pressure. The destination tank is
approximately at ambient temperature and 3,200 psi. The user could
have chosen to stop the process here but has decided to continue
until the vehicle/destination tank is full at 3,600 psi.
15. Therefore, system 10 begins to perform 5 series of Off-load
Process WAVE Phase II method steps as described above from Tank
1010 to Tank 1020, 1030, 1040, 1050, 1060, 1070 and 1080.
Phase II (SECOND TIME)
Off-Load Stage 2 WAVE
16. Valve 100 is rotated to Position 2. Gas at ambient temp from
tank 1010 at SP1, 150 psig flows through port 110 to compressor 500
hermetic housing 504. Compressor 500 which is still running
utilizes the gas of tank 1010 to compress into tank 1020.
Compressor 500 continues to run until the pressure in tank 1020
rises to be approximately 680 psi while SP1.3 becomes 138 psi.
Off-Load Stage 3 WAVE
17. The Valve 100 is rotated to Position 3. Gas at below ambient
temp from tank 1020, SP2.3 at 680 psi flows to compressor 500
hermetic housing 504. Compressor 500 which is still running
utilizes the gas of tank 1020 to compress into tank 1030.
Compressor 500 continues to run until the pressure in tank 1030
rises to be approximately 1,185 psi and the falling pressure of
tank 1020 is approximately 640 psi.
Off-Load Stage 4 WAVE
18. The Valve 100 is rotated to Position 4. Gas at ambient temp
from tank 1030, SP3.3 at 1,185 psi. flows to compressor 500
hermetic housing 504. Compressor 500 which is still running
utilizes the gas of tank 1030 to compress into tank 1040.
Compressor 500 continues to run until the pressure in tank 1040
rises to be approximately 1,680 psi and the falling pressure of
tank 1030 is approximately 1,150 psi.
Off-Load Stage 5 WAVE
19. The Valve 100 is rotated to Position 5. Gas at ambient temp
from tank 1040, SP4.3 at 1,680 flows to compressor 500 hermetic
housing 504. The Compressor 500 which is still running utilizes the
gas of tank 1040 to compress into tank 1050. Compressor 500
continues to run until the pressure in tank 1050 rises to be
approximately 2,085 psi and the falling pressure of tank 1040 is
approximately 1,590 psi.
Off-Load Stage 6 WAVE
20. The Valve 100 is rotated to Position 6. Gas at ambient temp
from tank 1050, SP5.3 at 2,085 psi flows to compressor 500 hermetic
housing 504. Compressor 500 which is still running utilizes the gas
of tank 1050 to compress into tank 1060. Compressor 500 continues
to run until the pressure in tank 1060 rises to be approximately
2,450 psi and the falling pressure of tank 1050 is approximately
1,985 psi.
Off-Load Stage 7 WAVE
21. The Valve 100 is rotated to Position 7. Gas at ambient temp
from tank 1060, SP6.3 at 2,450 psi flows to compressor 500 hermetic
housing 504. Compressor 500 which is still running utilizes the gas
of tank 1060 to compress into tank 1070. Compressor 500 continues
to run until the pressure in tank 1070 rises to be approximately
2,720 psi the falling pressure of tank 1060 is approximately 2,380
psi.
Off-Load Stage 8 WAVE
22. The Valve 100 is rotated to position 8. Gas at ambient temp
from tank 1070, SP7.3 at 2,720 psi. flows to compressor 500
hermetic housing 504. Compressor 500 which is still running
utilizes the gas of tank 1070 to compress into tank 1080.
Compressor 500 continues to run until the pressure in tank 1080
rises to be approximately 2,940 psi and the falling pressure of
tank 1070 is approximately 2,485 psi.
Phase III (SECOND TIME)
NOTE: This second accomplishment of the Off-load Process second
phase now has the system 10 ready for utilization of the Compressor
500 to move gas from tank 1080 to the vehicle
tank(s)/destination.
23. Valve 524 is closed, and valves 528 and 532 are opened.
24. Valve 100 is rotated to Position 9. Gas at ambient temp from
tank 1080 at 2,940, which is in equilibrium pressure with the
destination tank at approximately 3,420 psi, SP8.3 flows through
eighth selector port 110 of first family 109 to first selector port
260 of second family 209, and to compressor 500 hermetic housing
504. Compressor 500 continues to run until the pressure of tank
1080 decreases to SP8.2 which is approximately 200 psi less than
the starting pressure, and the destination tank is approximately at
3,300 psi.
25. The above "Second" series of Off-load Process WAVE Stages, for
this example, is repeated 4 more times. The pressure set points are
continually readjusted as the process proceeds. 26. This entire
Off-load Process, with the single (1) Off-load Transfer starting at
Stage 6, single (1) Off-load Process WAVE starting at Stage 5 and
then five (5) each Off-load Process WAVE starting at Stage 2 took
approximately 15 minutes for a 2/3rd full destination tank filling
to 3,600 psi.
27. Valve 532 is closed, and valves 524 and 528 are opened.
System Refresh Process Overview
This section will describe just a brief overview of the Replenish
Process (refilling of staged storage tank array 10), using the Work
Adjusted Volumetric Efficient (WAVE) methodology. Since the
quantity of gas is controlled such that there is never a true
desire to deplete the system, the remaining Stage pressures are
beneficial for the Refresh Process' ability to relatively quickly
and easily recover.
Example 4: Standard Wave, Option #5
This section will give the example of WAVE Option #5 where the set
point differences have been coincidentally reduced along with
smaller staging pressure changes. In general ambient temperature on
average exists for all components (conservatively accepted to be 80
degrees F.). The source gas valve 17 between the gas external
supply (House gas) 16 is opened. Gas flows through zero port 101 to
the valve 100 and to compressor 500 through port 270 into
compressor 500 hermetic housing 504.
System Refresh Process
Stage 1
1. Valve 100 is rotated to Position 1. Gas at ambient temp from the
external source flows to compressor 500 hermetic housing 504.
Compressor 500 which is still running utilizes the gas of the
external source to compress into tank 1010, targeting SP1.
Compressor 500 continues to run until the pressure in tank 1010
rises to SP1.
Refresh Stage 2 WAVE
2. Valve 100 is rotated to Position 2. Gas at ambient temp from
tank 1010 flows to compressor 500 hermetic housing 504. Compressor
500 which is still running utilizes the gas of tank 1010 to
compress into tank 1020. Compressor 500 continues to run until the
pressure in tank 1010 drops to SP1.1 at 100 psig, or until SP2.2,
which is set by system 10 to be less than SP2 for a WAVE Option #5,
is achieved.
Refresh Stage 3 WAVE
3. Valve 100 is rotated to Position 3. Gas at ambient temp from
tank 1020 flows to compressor 500 hermetic housing 504. Compressor
500 which is still running utilizes the gas of tank 1020 to
compress into tank 1030. Compressor 500 continues to run until the
pressure in tank 1020 drops to SP2.1 at 350 psig or until SP3.2,
which is set by the system to be less than SP3 for a WAVE Option
#5, is achieved.
Refresh Stage 4 WAVE
4. Valve 100 is rotated to Position 4. Gas at ambient temp from
tank 1030 flows to compressor 500 hermetic housing 504. Compressor
500 which is still running utilizes the gas of tank 1030 to
compress into tank 1040. Compressor 500 continues to run until the
pressure in tank 1030 drops to SP3.1 at 850 psig, or until SP4.2,
which is set by the system to be less than SP4 for a WAVE Option
#5, is achieved.
Refresh Stage 5 WAVE
5. Valve 100 is rotated to Position 5. Gas at ambient temp from
tank 1040 flows to the Compressor 500 hermetic housing 504.
Compressor 500 which is still running utilizes the gas of tank 1040
to compress into tank 1050. Compressor 500 continues to run until
the pressure in tank 1040 drops to SP4.1 at 1350 psig, or until
SP5.2, which is set by the system to be less than SP5 for a WAVE
Option #5, is achieved.
Refresh Stage 6 WAVE
6. Valve 100 is rotated to Position 6. Gas at ambient temp from
tank 1050 flows to compressor 500 hermetic housing 504. Compressor
500 which is still running utilizes the gas of tank 1050 to
compress into tank 1060. Compressor 500 continues to run until the
pressure in tank 1050 drops to SP5.1 at 1850 psig, or until SP6.2,
which is set by the system to be less than SP6 for a WAVE Option
#5, is achieved.
Refresh Stage 7 WAVE
7. Valve 100 is rotated to Position 7. Gas at ambient temp from
tank 1060 flows to compressor 500 hermetic housing 504. Compressor
500 which is still running utilizes the gas of tank 1060 to
compress into tank 1070. Compressor 500 continues to run until the
pressure in tank 1060 drops to SP6.1 at 2350 psig, or until SP7.2,
which is set by the system to be less than SP7 for a WAVE Option
#5, is achieved.
Refresh Stage 8 WAVE
8. Valve 100 is rotated to Position 8. Gas at ambient temp from
tank 1070 flows to compressor 500 hermetic housing 504. Compressor
500 which is still running utilizes the gas of tank 1070 to
compress into tank 1080. Compressor continues to run until the
pressure in tank 1070 drops to SP7.1 at 2850 psig, or until SP8.2,
which is set by the system to be less than SP8 for a WAVE Option
#5, is achieved.
9. All System Refresh Stage WAVE process steps above are performed
120 times over a 48 hour period. Pressure of all tanks are back up
to their initial set points SP1, SP2, SP3, SP4, SP5, SP6, SP7, and
SP8.
Example 5: Reverse Wave, Option #3
The Off-load Process delivered a quantity of gas to the vehicle
(example here shows a destination tank of 100 L, arriving for a
fill at approximately 3420 psi.). System 10 determines that the
tank current pressures and assigns new set points to those values
that are no longer at their initially defined SP1, SP2, SP3, SP4,
SP5, SP6, SP7, and SP8 for the original fill described above. Since
the pressure of tank 1080 is approximately 3,175 psi which is below
its SP8.1, a new SP8.3 is established and system 10 uses controller
2000 to operate motor to rotate valve 100 to Position 7, and
compressor 500 is started.
Refresh Stage 8 WAVE
5. Valve 100 is rotated to Position 7. Gas at ambient temp from
tank 1070 flows to compressor 500 hermetic housing 504. Compressor
500 which is still running utilizes the gas of tank 1070 to
compress into tank 1080, targeting SP8. Compressor 500 continues to
run until the pressure in tank 1080 rises to be approximately 500
psig higher than the falling pressure of tank 1070. Tank 1080 is
approximately at 3,390 psi, which is above SP8.2, and tank 1070 is
approximately at 2,790 psi, which is below SP7.1 and is now labeled
SP7.3.
6. System 10 is now at a point where it knows the other tanks are
at their SP#0.2, and it also recognizes that there is less than a
350 psi differential between the current tank and the next lower
tank. System 10 therefore "backs down" through the tanks and
performs a WAVE Option #3 process to the next lower numbered
tank.
Note: If the quantity of gas used from each lower tank was greater
than a 350 psi differential due to the fact that the
vehicle/destination tank had a greater System 10 Fill Process
demand, then the system could decide to return directly to Position
1 (Port 110) and begin performing a Fill Process WAVE as described
above.
Refresh Stage 7 WAVE
10. Valve 100 is rotated to Position 7. Gas at ambient temp from
tank 1060 flows to compressor 500 hermetic housing 504. Compressor
500 which is still running utilizes the gas of tank 1060 to
compress into tank 1070, targeting SP7. Compressor 500 continues to
run until the pressure in tank 1070 rises to be approximately 500
psig higher than the falling pressure of tank 1060. If SP7 is
achieved then this Refresh Stage 7 WAVE process is stopped and the
system proceeds to Refresh Stage 6 WAVE
Refresh Stage 6 WAVE
11. Valve 100 is rotated to Position 6. Gas at ambient temp from
tank 1050 flows to compressor 500 hermetic housing 504. Compressor
500 which is still running utilizes the gas of tank 1050 to
compress into tank 1060, targeting SP6. Compressor 500 continues to
run until the pressure in tank 1060 rises to be approximately 500
psig higher than the falling pressure of tank 1050. If SP6 is
achieved then this Refresh Stage 6 WAVE process is stopped and the
system proceeds to Refresh Stage 5 WAVE.
Refresh Stage 5 WAVE
12. Valve 100 is rotated to Position 5. Gas at ambient temp from
tank 1040 flows to compressor 500 hermetic housing 504. Compressor
500 which is still running utilizes the gas of tank 1040 to
compress into tank 1050, targeting SP5. Compressor 500 continues to
run until the pressure in tank 1050 rises to be approximately 500
psig higher than the falling pressure of tank 1040. If SP5 is
achieved then this Refresh Stage 5 WAVE process is stopped and the
system proceeds to Refresh Stage 4 WAVE.
Refresh Stage 4 WAVE
13. Valve 100 is rotated to Position 4. Gas at ambient temp from
tank 1030 flows to compressor 500 hermetic housing 504. Compressor
500 which is still running utilizes the gas of tank 1030 to
compress into tank 1040, targeting SP4. Compressor 500 continues to
run until the pressure in tank 1040 rises to be approximately 500
psig higher than the falling pressure of tank 1030. If SP4 is
achieved then this Refresh Stage 4 WAVE process is stopped and the
system proceeds to Refresh Stage 3 WAVE.
Refresh Stage 3 WAVE
14. Valve 100 is rotated to Position 3. Gas at ambient temp from
tank 1020 flows to compressor 500 hermetic housing 504. Compressor
500 which is still running utilizes the gas of tank 1020 to
compress into tank 1030, targeting SP3. Compressor 500 continues to
run until the pressure in tank 1030 rises to be approximately 500
psig higher than the falling pressure of tank 1020. If SP3 is
achieved then this Refresh Stage 3 WAVE process is stopped and the
system proceeds to Refresh Stage 2 WAVE.
Refresh Stage 2 WAVE
15. Valve 100 is rotated to Position 2. Gas at ambient temp from
tank 1010 flows to compressor 500 hermetic housing 504. Compressor
500 which is still running utilizes the gas of tank 1010 to
compress into tank 1020, targeting SP2. Compressor continues to run
until the pressure in tank 1020 rises to be approximately 500 psig
higher than the falling pressure of tank 1010. If SP2 is achieved
then this Refresh Stage 2 WAVE process is stopped and the system
proceeds to Refresh Stage 1.
16. System 10 reviews the system set points and determines if a
Fill Process WAVE Option#2 is required. For this particular
Off-load case to a 95% full vehicle or destination tank(s) the
System 10 System needs to perform 5 each complete system Fill
Process WAVE methods from Stage 1 to Stage 8. Since staged storage
tank array 1000 was only marginally diminished from Stage 8, the
time to complete this entire Refresh Process will only be 2.2
hours
Example 6: WAVE Option #2 Process--System Refresh Stage 1 WAVE
17. Valve 100 is rotated to Position 1. Gas at ambient temp from
the external source flows to compressor 500 hermetic housing 504.
Compressor 500 which is still running utilizes the gas of the
external source to compress into tank 1010, targeting SP1.
Compressor 500 continues to run until the pressure in tank 1010
rises to SP1.
Refresh Stage 2 WAVE
18. Valve 100 is rotated to Position 2. Gas at ambient temp from
tank 1010 flows to compressor 500 hermetic housing 504. Compressor
500 which is still running utilizes the gas of tank 1010 to
compress into tank 1020. Compressor 500 continues to run until the
pressure in tank 1010 drops to SP1.1 at 100 psig, or until SP2 is
achieved.
Refresh Stage 3 WAVE
19. Valve 100 is rotated to Position 3. Gas at ambient temp from
tank 1020 flows to compressor 500 hermetic housing 504. Compressor
500 which is still running utilizes the gas of tank 1020 to
compress into tank 1030. Compressor 500 continues to run until the
pressure in tank 1020 drops to SP2.1 at 350 psig or until SP3 is
achieved.
Refresh Stage 4 WAVE
20. Valve 100 is rotated to Position 4. Gas at ambient temp from
tank 1030 flows to the Compressor 500 hermetic housing 504.
Compressor 500 which is still running utilizes the gas of tank 1030
to compress into tank 1040. Compressor 500 continues to run until
the pressure in tank 1030 drops to SP3.1 at 850 psig, or until SP4
is achieved.
Refresh Stage 5 WAVE
21. Valve 100 is rotated to Position 5. Gas at ambient temp from
tank 1040 flows to compressor 500 hermetic housing 504. Compressor
500 which is still running utilizes the gas of tank 1040 to
compress into tank 1050. Compressor 500 continues to run until the
pressure in tank 1040 drops to SP4.1 at 1350 psig, or until SP5 is
achieved.
Refresh Stage 6 WAVE
22. Valve 100 is rotated to Position 6. Gas at ambient temp from
tank 1050 flows to the Compressor 500 hermetic housing 504.
Compressor 500 which is still running utilizes the gas of tank 1050
to compress into tank 1060. Compressor 500 continues to run until
the pressure in tank 1050 drops to SP5.1 at 1850 psig, or until SP6
is achieved.
Refresh Stage 7 WAVE
23. Valve 100 is rotated to Position 7. Gas at ambient temp from
tank 1060 flows to compressor 500 hermetic housing 504. Compressor
500 which is still running utilizes the gas of tank 1060 to
compress into tank 1070. Compressor 500 continues to run until the
pressure in tank 1060 drops to SP6.1 at 2350 psig, or until SP7 is
achieved.
System Refresh Stage 8 WAVE
24. Valve 100 is rotated to Position 8. Gas at ambient temp from
tank 1070 flows to compressor 500 hermetic housing 504. Compressor
500 which is still running utilizes the gas of tank 1070 to
compress into tank 1080. Compressor 500 continues to run until the
pressure in tank 1070 drops to SP7.1 at 2850 psig, or until SP8 is
achieved.
25. All system 10 Refresh Stage WAVE process steps above are
performed 5 times over a 2 hour period, for a process subtotal
runtime of approximately 2.2 hours, and this brings the pressure of
all tanks back up to their initial set points SP1, SP2, SP3, SP4,
SP5, SP6, SP7, and SP8.
System Wave Direction Choices or Options
The above examples of System Fill Process, Off-load Process, and/or
Refresh Processes can be accomplished via a multiplicity of
methodologies. Below are described five possibilities.
WAVE Option Number 1--
A methodology is to start at the lower tank pressure value, such as
tank 1 (1010) and then pressurize into several lower pressured
tanks simultaneously 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12 . . . as
described in the method steps associated with the initial System
Fill WAVE process for system 10. That example starts by using gas
from Tank 1 to pressurize into Tanks 2, 3, 4, 5, 6, 7, and 8
simultaneously up to the predefined pressurized set point pressure
SP2 for staged Tank 2 of staged tank array 1000. Gas from tank 1010
at this stage will serve as the suction gas for compressor 500, and
second tank 1020 will receive the discharge of compressor 500.
Because check valves 1024, 1034, 1044, 1054, 1064, 1074, and 1084
respectively fluidly connect in a one way (e.g., increasing)
direction tanks 1030, 1040, 1050, 1060, 1070, and 1080 to each
other (tank 1030 to 1040, 1040 to 1050, 1050 to 1060, 1060 to 1070,
and 1070 to 1080) allowing higher pressure gas to flow from lower
numbered tanks to higher numbered tanks assuming that the minimum
check valve activation pressure can be overcome) at this stage gas
from tank 1010, although primarily discharging to tank 1020
(through second port 110), Compressor 500 discharge gas also
indirectly flows also to tanks 1030, 1030, 1040, 1050, 1060, 1070,
and 1080. Because tank 1020 is at a higher pressure than tank 1020,
check valve 1014 will prevent flow from tank 1020 to tank 1010. The
system then proceeds to Tank 2 (1020) as suction for compressor 500
and discharges into Tanks 3, 4, 5, 6, 7, and 8 etc. (where
discharge is primarily directed to Tank 3 up to predefined
pressurized set point pressure SP3, but check valves 1034, 1044,
1054, 1064, 1074, etc. allow higher pressure to bleed into the
higher numbered tanks of staged tank array 1000. The next step
would be to use Tank 3 (1030) as the suction to pressurize as
suction for compressor 500 and discharges into Tanks 4, 5, 6, 7,
and 8 etc. This upwardly staging process is performed until staged
tank array has the following upwardly staged set point pressures:
Tank 1--SP1; Tank 2--SP3; Tank 3--SP3; Tank 4--SP4; Tank 5--SP5;
Tank 6--SP6; Tank 7--SP7; and Tank 8--SP8.
WAVE Option Number 2--
A methodology is to start at a lower tank pressure value, such as
tank 1 and then proceed up to tank 8, while only pressurizing into
one upstream destination tank at one time. An example of is found
in the method steps for the System Refresh Process where gas from a
lower pressure tank is placed into the next higher tank, and then
the system proceeds to take that pressurized gas and compress it
into only the next highest tank. That example appears as having the
valve 100 rotated to Position 1. Gas at ambient temp from the
external source 16 flows to compressor 500 hermetic housing 504,
and compressor 500, which is still running, utilizes the gas of the
external source 16 to compress into tank 1010, targeting SP1.
Compressor 500 continues to run until the pressure in tank 1010
rises to SP1. System 10 then proceeds to the next WAVE Stage and
valve 100 is rotated to Position 2. Gas at ambient temp from tank
1010 flows to compressor 500 hermetic housing 504, and compressor
500, which is still running, utilizes the gas of tank 1010 to
compress into tank 1020. Compressor 500 continues to run until the
pressure in tank 1010 drops to SP1.1 at 100 psig, or until SP2 is
achieved etc. Another example of this WAVE Option #2 method is
found in the methods outlined in the System Off-load Process where
gas from Tank 8 is Compressor 500 pressurized by the limiting delta
P amount into the vehicle/destination tank.
Reverse WAVE Option Number 3--
a methodology is to perform a Reverse WAVE where system 10
pressurizes gas from the next lower tank up to the existing
positioned tank, then repositions valve 100 to the next lower
position and backs-down the stages while it is quickly replenishing
more dense gas to the top stages. The Refresh Process or Off-load
Processes can employ this methodology for two special but not
limiting cases: (1) allowing for a quick refresh of the upper
staged pressurized tanks in staged tank array 1000 for potential
immediate needs by a second vehicle or second destination need; and
(2) quickly translating higher density gas up the staged tank array
1000 to make room for another System Fill Process WAVE. That
example starts with gas at ambient temp from tank 1060 flows to
compressor 500 hermetic housing 504 and compressor 500 which is
running utilizes the gas of tank 1060 to compress into tank 1070,
targeting SP7. Compressor 500 continues to run until the pressure
in tank 1070 rises to be approximately 500 psig higher than the
falling pressure of tank 1060. If SP7 is achieved then this Refresh
Stage 7 WAVE process is stopped and system 10 proceeds to Refresh
Stage 6 WAVE where gas at ambient temp from tank 1050 flows to
compressor 500 hermetic housing 504, and compressor 500, which is
running, utilizes the gas of tank 1050 to compress into tank 1060,
targeting SP6. Compressor 500 continues to run until the pressure
in tank 1060 rises to be approximately 500 psig higher than the
falling pressure of tank 1050. If SP6 is achieved then this Refresh
Stage 6 WAVE process is stopped and the system proceeds to Refresh
Stage 5 WAVE etc.
Mid WAVE Option Number 4--
a methodology is to choose to start and/or stop a given process at
some other determinable point in the pressurized staged tank array
1000. An example of this is described in the System Off-load
Process for a 95% full vehicle fill where system 10 has determined
the destination tank 22 only needed gas from tank 1080 and system
10 decided to perform an System Off-load to destination tank 22
using only Tank 1080. In the Off-load Process for a vehicle 20 that
is two thirds full, system 10 determined to start the offloading
process with Tank 1040 to destination tank 22 until system 10 found
the actual tank from the pressurized staged tank array 1000 at
which the gas began offloading flow from the pressurized tank to
the destination stank (i.e., because the pressure in the
pressurized tank of the staged tank array 1000 is higher than the
pressure in the destination tank 22). Once vehicle 20 was filled by
the Off-load Process Phase I methods, system 10 then determined it
only needed to start the Off-load Process Phase II by utilizing an
Off-load Process WAVE starting with Stage 6. If the user is
time-bound then the user could have chosen to complete the
vehicle/destination Off-load Process after this initial 2 minutes,
and thereby precluded waiting an additional 13 minutes for a
vehicle/destination complete fill to 3600 psig. The methodology
example described in the two thirds full destination Off-load
Process is one where the system decided it was best to perform a
multiplicity of Process methodologies.
WAVE Option Number 5--
a methodology is to raise stage pressures at smaller differential
pressure increments. System 10 can increase an upper stage's
pressure by using smaller incremental differential steps than
outlined in the initial System Fill WAVE Option #1. It would
utilize the same process and methodology for establishing the
second set of set points, and the same processing methodology with
regards to choosing other available WAVE Options, just at lower
differential pressure values. WAVE Options 1, 2, 3 and 4 can each
employ Option Number 5 if and as needed.
The versatility of these highly unique processes, in part or in
total, acting as a method for using single stage compressor 500
with staged tank array 1000 in simulating a multi-staged compressor
gives the user the abilities not previously afforded, to make
choices with regards to time to wait, instantaneous choice of
quantity of gas for a particular vehicle or destination tank fill
or off-load, choice of quantity of immediately available gas for
the immediate transfer to another vehicle/destination, gives an
ability to choose either a lengthy or reduced time-to-refresh need
for the System, for the next system use while the user's vehicle is
no longer still interfaced/attached for lengthy periods of time
with the unit.
Fill Capacity Determination of Destination Tank
There are various ways for controller 2000 the system 10 and
therefore destination tank's 22 current state of charge, and
subsequently be able to calculate its needed capacity. System 10
understands (by industry understood methods) what the 1000 storage
array pressures are and therefore can predict system's 10 capacity
for a given destination need. Correspondingly, while controller
2000 is processing it has the ability to estimate the destination
tank's 22 need, and can, as needed assign new set points (SP1
becomes SP1.3, SP1.1 becomes SP1.2, etc.) so as to recalculate both
estimated run-time of the system to achieve a filled condition, and
to establish a temporary tank target pressure that is achievable by
compressor 500. These new set points are then utilized
proportionally until the unit is able to utilize the WAVE Stage
Processes to return the storage medium 1000 back to their
respective Fill Process principle set-points (SP1, SP2, SP3 . . .
)
System 10, though use of controller 2000 and remote control panel
2100, is thereby able to alert the user as to when the projected
System Full status will be re-established, how much time it will
take to complete a complete filling of the destination tank etc.
The system is thereby able to real-time report the available system
destination tank(s) filling capability, the amount available
immediately or in the future for the user at any given time between
fill-ups. This functionality is usable by a host of applications
such as PDA, cell phones, home or remote computers, fire alarm
system companies, fire department notifications, maintenance
systems or personnel, local and federal authorities, etc.
In addition to the system's ability to approximate, then measure
and then refine the destination tank's 22 needs, system 10 is also
able to accept direct user input as a more direct method of knowing
the given conditions:
There is method of human interface to input to system 10 the user
known destination tank 22 size or volume.
There is the method of human interface to input to system 10 the
user known current destination tank 22 pressure.
There is the method of human interface to input to system 10 the
user known vehicle 20 type and year.
There is the method of human interface to input to system 10
whether the user prefers to only perform a quick fill in less than
a few minutes, or to proceed with a complete fill lasting
approximately 15 minutes. System 10 therefore then knows the
potential capacity maximum needs for the destination tank(s) 22 and
is also able to jointly communicate back to the use the potential
options available for choosing, system 10 needed maintenance,
system 10's health, etc.
As system 10 performs an Off-load Process the pressure differences
of gas from any given stage then establishes the destination
tank(s)'s 22 minimum pressure starting state. Additionally system
10 knows the unit's post operation current array 1000 pressures and
can label then as SP1.3, SP2.3, SP3.3, SP4.3, etc. These are
momentarily considered to be the new "High" set points, and
establishes new "Low" set points SP1.2, SP2.2, SP3.2, etc. The
system then utilizes, via obvious to the industry methodologies to
know the approximate needed quantity of gas for the destination,
and the system is then able to decide how many WAVE Off-load
Processes to accomplish and to which options are to be
utilized.
The following is a list of reference numerals:
TABLE-US-00004 LIST FOR REFERENCE NUMERALS (Reference No.)
(Description) 10 system 12 inlet 14 outlet 15 housing 16 gaseous
fuel supply 17 valve 18 check valve 20 vehicle 22 storage tank 40
separator/filter 42 valve 50 cooling system 53 tee connection 100
valve assemby 101 port zero, where selector is in zero position 102
first opening of zero port 104 conduit between openings 106 second
opening zero port 109 first family of ports 110 first port, where
selector is in position 1 112 first opening of first port 114
conduit between openings 116 second opening first port 117 angle
120 second port, where selector is in position 2 122 first opening
of second port 124 conduit between openings 126 second opening
second port 127 angle 130 third port, where selector is in position
3 132 first opening of third port 134 conduit between openings 136
second opening third port 137 angle 140 fourth port, where selector
is in position 4 142 first opening of fourth port 144 conduit
between openings 146 second opening fourth port 147 angle 150 fifth
port, where selector is in position 5 152 first opening of fifth
port 154 conduit between openings 156 second opening fifth port 157
angle 160 sixth port, where selector is in position 6 162 first
opening of sixth port 164 conduit between openings 166 second
opening sixth port 167 angle 170 seventh port, where selector is in
position 7 172 first opening of seventh port 174 conduit between
openings 176 second opening seventh port 177 angle 180 eighth port,
where selector is in position 8 182 first opening of eighth port
184 conduit between openings 186 second opening eights port 187'
angle 187'' angle 200 body or selector rotor housing 204 plurality
of openings 209 second family of ports 210 top 212 bottom 214 outer
periphery 216 seal recess 220 selector recess 222 side wall of
selector recess 224 base of selector recess 240 trunnion recess 250
relative rotational axis between body and selector 260 first
conduit 262 first connector of first conduit 264 pathway between
connectors 266 second connector of first conduit 270 second conduit
272 first connector of second conduit 274 pathway between
connectors 276 second connector of second conduit 290 annular
recess/cavity 300 port selector rotor 304 rotational axis 310 upper
surface 314 rod 316 arrow 320 lower surface 321 upper rod or shaft
seal 322 lower rod or shaft seal 323 family isolating seal 324
trunnion 325 seal for trunnion 330 outer periphery 360 first
conduit 362 first connector of first conduit 364 pathway between
connectors 366 second connector of first conduit 370 second conduit
372 first connector of second conduit 374 pathway between
connectors 376 second connector of second conduit 380 angle 390
cavity for second conduit selector 400 top porting manifold 404
plurality of openings 410 upper 412 lower 414 outer periphery 420
opening for rod of selector 430 plurality of selector porting 450
plurality of check valve porting 500 gas compressor 504 body 506
interior 510 input or suction line for compressor 512 check valve
for input to compressor 520 output or discharge line for compressor
521 output from filter separatort 522 output valve 524 valve 528
valve 529 line 532 valve to vehicle fill 540 motor 550 cylinder 560
piston 570 chamber 572 input 573 check valve for input to
compression chamber 574 output 575 check valve for discharge from
compression chamber 1000 storage tank array 1010 tank 1 1013 valve
for tank 1 1014 check valve (zero port to tank 1) and normally used
in dual compression system (e.g., FIG. 6) 1015 check valve port
first end 1016 check valve port second end 1020 tank 2 1023 valve
for tank 2 1024 check valve (tank 1 to tank 2) 1025 check valve
port first end 1026 check valve port second end 1027 shutoff valve
1030 tank 3 1033 valve for tank 3 1034 check valve (tank 2 to tank
3) 1035 check valve port first end 1036 check valve port second end
1040 tank 4 1043 valve for tank 4 1044 check valve (tank 3 to tank
4) 1045 check valve port first end 1046 check valve port second end
1050 tank 5 1053 valve for tank 5 1054 check valve (tank 4 to tank
5) 1055 check valve port first end 1056 check valve port second end
1060 tank 6 1063 valve for tank 6 1064 check valve (tank 5 to tank
6) 1065 check valve port first end 1066 check valve port second end
1070 tank 7 1073 valve for tank 7 1074 check valve (tank 6 to tank
7) 1075 check valve port first end 1076 check valve port second end
1080 tank 8 1083 valve for tank 8 1084 check valve (tank 7 to tank
8) 1085 check valve port first end 1086 check valve port second end
1200 arrow 1210 arrow 1220 arrow 1230 arrow 1240 arrow 1250 arrow
1260 arrow 1270 arrow 1300 high pressure connector/seal 1310
threaded connection 1320 flexible connector 1330 flared metal tube
1340 cavity 1400 valve 1410 valve 2000 controller 2100 remote
control panel 5000 compressor (which operates as a pre-compressor)
5100 compressor output tank (can also operate as a oil/liquid
recovery system for pre-compressor)
All measurements disclosed herein are at standard temperature and
pressure, at sea level on Earth, unless indicated otherwise.
It will be understood that each of the elements described above, or
two or more together may also find a useful application in other
types of methods differing from the type described above. Without
further analysis, the foregoing will so fully reveal the gist of
the present invention that others can, by applying current
knowledge, readily adapt it for various applications without
omitting features that, from the standpoint of prior art, fairly
constitute essential characteristics of the generic or specific
aspects of this invention set forth in the appended claims. The
foregoing embodiments are presented by way of example only; the
scope of the present invention is to be limited only by the
following claims.
* * * * *